Polaris RANGER XP 900 2018-2019 Service Manual
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Polaris RANGER XP 900 2018-2019 Service Manual

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2018-2019 RANGER XP/ CREW 900/1000
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed 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.

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Summary of Contents for Polaris RANGER XP 900 2018-2019

  • Page 1 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.
  • Page 2 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 injury.
  • Page 3 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 DATE...
  • Page 4 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...

  • Page 5: Table Of Contents

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

  • Page 6: Reference Information

    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.

  • Page 7: Publication Numbers

    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. 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.

  • Page 8: 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/...

  • Page 9: Special Tools Index

    With 2” Bore Stand) PU-50562 PU-50625 Engine Stand Sleeve Adapter (Use Engine Stand (2” Bore) Clutch Center Distance Tool With 2.375” Bore Stand) PU-50624 PU-50658-A PW-47054 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 10 GENERAL INFORMATION CHAPTER 3 — ENGINE / COOLING SYSTEM Oil Pressure Gauge Adapter Oil Pressure Gauge Cylinder Holding & Camshaft Timing PV-43531 Plate PU-52492 PU-50563 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 11 Valve Spring Compressor Adapter Flywheel Puller Piston Ring Compressor Pliers PV-43513-A PA-49316 PV-43570-1 Spring Puller Mityvac® Pressure Test Tool Water Pump Mechanical Seal PU-45485 2870975 Installer PU-50564 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 12 Fuel Pressure Gauge Adapter Fuel Pump Service Tool PU-43506-A PS-48762 PU-50326 Digital Wrench® Diagnostic Kit Digital Wrench® Software Digital Wrench® Standard Interface PU-47063-B PU-48731 Cable PU-47151 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 13 Digital Wrench® PC Interface Cable Cable PU-47470 PU-50621 PU-47471 Digital Wrench® Vehicle Interface Digital Wrench® SmartLink Module Wireless Vehicle Link (WVL) Cable PU-47468 PU-51435 PU-47469 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 14 Drive Clutch Spider Removal and Piston Pin Puller Bushing Replacement Tool 2870386 PA-47336 Installation Tool 2870341 Roller Pin Tool Universal Clutch Compressor 2870910 PU-50518 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.10 © Copyright Polaris Industries Inc.
  • Page 15 Rear Driveshaft Seal Guide PA-50231 2871698 2871699 CHAPTER 7 — FINAL DRIVE Roll Pin Removal Tool Axle Boot Clamp Tool CV Boot Clamp Pliers 2872608 PU-48951 8700226 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.11 © Copyright Polaris Industries Inc.
  • Page 16 Shock Spanner Wrench PU-50506 2870623 2871095 CHAPTER 9 — BRAKE SYSTEM Mityvac® Pressure Test Tool 2870975 CHAPTER 10 — BODY / FRAME Multi-Function Pliers 2876389 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.12 © Copyright Polaris Industries Inc.
  • Page 17 Hall Effect Sensor Probe Harness Multimeter 2871745 2460761 PF-51237 Battery Conductance Analyzer Connector Test Kit Timing Light 2870630 (MDX-610P) PV-43526 PU-50296 Relay Bypass PU-49466 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.13 © Copyright Polaris Industries Inc.

  • Page 18: Master Torque List

    44 lb-ft (60 Nm) Mounting Bolts Step 4–7 Oil Cooler Retaining Bolts 7 lb-ft (10 Nm) Front Engine Mount 40 lb-ft (54 Nm) Fasteners 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.14 © Copyright Polaris Industries Inc.
  • Page 19 Compressor High 18 lb-ft (24 Nm) Screws Pressure Hose Ignition Coil Retaining 8 lb-ft (11 Nm) Compressor Mounting 37 lb-ft (50 Nm) Bolt Fasteners 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.15 © Copyright Polaris Industries Inc.
  • Page 20 110 lb-ft (149 Nm) 17 lb-in (2 Nm) Clamps Nuts Lower Intake Plenum Rear Caliper Mounting 46 lb-ft (62 Nm) 22 lb-ft (30 Nm) Fastener Bolts 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.16 © Copyright Polaris Industries Inc.
  • Page 21 60 lb-ft (81 Nm) Wheels) Nerf Bar Fasteners 12–15 lb-ft (16–20 Nm) Wheel Nuts (Cast 120 lb-ft (163 Nm) Winch Fasteners 25 lb-ft (34 Nm) Aluminum Wheels) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.17 © Copyright Polaris Industries Inc.
  • Page 22 20-25 lb-in (2.3-2.8 Nm) Terminal Block Nuts 7 lb-ft (10 Nm) Starter Motor Fasteners 7 ± 1 lb-ft (10 ± 1 Nm) Thermostat Cover Bolts 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.18 © Copyright Polaris Industries Inc.

  • Page 23: Vehicle Identification

    * 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 1.19 © Copyright Polaris Industries Inc.

  • Page 24: Vehicle And Engine Serial Number Locations

    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 head...

  • Page 25: Vehicle Specifications

    50-State: 1100 lb / 499 kg cargo and accessories) Hitch Towing Capacity 2000 lb / 907 kg Hitch Tongue Capacity 150 lb / 68 kg 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.21 © Copyright Polaris Industries Inc.

  • Page 26: 2018-19 Ranger Xp 900 / Eps Specifications

    20 Amp: Fan Motor Circuit Breaker 10 Amp: Brake Lights:, Drive, Fuel Pump Fuses 20 Amp: Accessory, ECM, *Not in Fuse/Relay Box Lights 30 Amp: EPS (OPT)* 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.22 © Copyright Polaris Industries Inc.

  • Page 27: 2018-19 Ranger Crew Xp 900 / Eps Overview

    50-State: 1350 lb / 712 kg cargo and accessories) Hitch Towing Capacity 2000 lb / 907 kg Hitch Tongue Capacity 150 lb / 68 kg 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.23 © Copyright Polaris Industries Inc.

  • Page 28: 2018-19 Ranger Crew Xp 900 / Eps Specifications

    20 Amp: Fan Motor Circuit Breaker 10 Amp: Brake Lights:, Drive, Fuel Pump Fuses 20 Amp: Accessory, ECM, *Not in Fuse/Relay Box Lights 30 Amp: EPS (OPT)* 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.24 © Copyright Polaris Industries Inc.

  • Page 29: 2018 Ranger Xp 1000 High Lifter Overview

    50-State: 1100 lb / 499 kg cargo and accessories) Hitch Towing Capacity 2000 lb / 907 kg Hitch Tongue Capacity 150 lb / 68 kg 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.25 © Copyright Polaris Industries Inc.

  • Page 30: 2018 Ranger Xp 1000 High Lifter Specifications

    20 Amp: Fan Motor Circuit Breaker 10 Amp: Brake Lights:, Drive, Fuel Pump Fuses 20 Amp: Accessory, ECM, *Not in Fuse/Relay Box Lights 30 Amp: EPS (OPT)* 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.26 © Copyright Polaris Industries Inc.
  • Page 31 50-State: 1350 lb / 712 kg cargo and accessories) Hitch Towing Capacity 2000 lb / 907 kg Hitch Tongue Capacity 150 lb / 68 kg 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.27 © Copyright Polaris Industries Inc.
  • Page 32 20 Amp: Fan Motor Circuit Breaker 10 Amp: Brake Lights:, Drive, Fuel Pump Fuses 20 Amp: Accessory, ECM, *Not in Fuse/Relay Box Lights 30 Amp: EPS (OPT)* 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.28 © Copyright Polaris Industries Inc.

  • Page 33: Clutch Chart

    (7044111) 2018 1000 Models 0-1800 Meters 27-98 Black 3235964 (0-6000 Feet) (5140604) (7044655) 1800-3700 Meters 27-89 Black 3235964 (6000 - 12000 Feet) (5138015) (7044655) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.29 © Copyright Polaris Industries Inc.

  • Page 34: Misc. Specifications And Charts

    π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.30 © Copyright Polaris Industries Inc.

  • Page 35: Standard Bolt Torque Specification

    151 (205) 177 (240) 59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.31 © Copyright Polaris Industries Inc.

  • Page 36: Sae Tap / Drill Sizes

    1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.32 © Copyright Polaris Industries Inc.

  • Page 37: Decimal Equivalents

    0.5313″ 35/64 0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.33 © Copyright Polaris Industries Inc.
  • Page 38 GENERAL INFORMATION NOTES 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 1.34 © Copyright Polaris Industries Inc.
  • Page 39 .......2.13 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS GENERAL VEHICLE INSPECTION AND MAINTENANCE..........2.14 .
  • Page 40 ................. . .2.40 SPARK PLUG SERVICE 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 41: 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.

  • Page 42: Service Specifications - Maintenance

    Engine Coolant 50 / 50 Extended Life Antifreeze 5 Qt (4.7 L) Fuel 87 Octane (minimum) 10 Gal (37.8 L) Brake / Clutch Fluid DOT 4 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 43: Periodic Maintenance Chart

    Improperly performing the procedures marked ■ could Severe Use Definition result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these • Frequent immersion in mud, water or sand services. • Racing or race-style high RPM use •...

  • Page 44: Pre-Ride Inspection

    • Verify coolant level is filled to the FULL COLD mark on Coolant Level coolant reservoir (if engine is cold) • Inspect hoses and radiator for leaks Auxiliary Brake (if equipped) Inspect / adjust as needed 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 45 Inspect / clean often Power Steering Unit Inspect / clean often Clean when driving in mud and water; replace a cracked Spark Arrester or damaged arrester before operating 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 46: 10 - 50 Hour Maintenance Interval

    Shift Cable / Linkage 500 (800) Inspect, lubricate, adjust 50 H Steering 500 (800) ■ 50 H Lubricate Front / Rear Suspension 500 (800) ▶ 50 H Lubricate 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 47 Valve Clearance 500 H Replace coolant ▶ Coolant 60 M Inspect periodically; adjust when parts are Toe Adjustment ■ replaced Headlight Aim Adjust as needed 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 48: Maintenance Quick Reference

    Coolant in coolant reservoir Radiator bottle and radiator. * More often under severe use, such as operation in water or under severe loads. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.10 © Copyright Polaris Industries Inc.
  • Page 49 Add lubricant until it is visible at first Transmission Polaris AGL the fill hole threads * More often under severe use, such as operation in water or under severe loads. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.11 © Copyright Polaris Industries Inc.

  • Page 50: Grease Lubrication Points

    Polaris All Season Grease Grease the fitting thoroughly washing or Propshaft Yoke (3 pumps maximum) submerging the vehicle NON-CREW MODELS CREW MODELS 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.12 © Copyright Polaris Industries Inc.

  • Page 51: Service Products And Lubricants

    MAINTENANCE SERVICE PRODUCTS AND LUBRICANTS POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS PART NO. DESCRIPTION PART NO. DESCRIPTION Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. Fogging Oil (12 oz. Aerosol) Loctite® Threadlock 242 2870791 2871950 (6 ml.) (12 count)

  • Page 52: General Vehicle Inspection And Maintenance

    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 2.14 © Copyright Polaris Industries Inc.

  • Page 53: Engine Maintenance

    Access the oil dipstick and oil fill cap by tilting the rear dipstick tube to keep the depth of the dipstick cargo box. consistent. Polaris recommends the use of PS-4 Synthetic or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil. 7. Remove the dipstick and check the oil level. FLUID CAPACITY 8.
  • Page 54 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 2.16 © Copyright Polaris Industries Inc.

  • Page 55: Engine Crankcase Breather Hose Inspection

    21. When finished, reinstall the oil fill cap, oil dipstick and If leakage exceeds service limit, inspect the engine for lock the lever. the cause. 22. Dispose of used oil and filter properly. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.17 © Copyright Polaris Industries Inc.

  • Page 56: Valve Clearance Inspection

    5. Remove the four T-40 bolts and rubber isolators retaining the valve cover . Note the location and use of the grounding washer for assembly. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.18 © Copyright Polaris Industries Inc.

  • Page 57: Cam Chain Tensioner Inspection

    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 2.19 © Copyright Polaris Industries Inc.

  • Page 58: Exhaust - Spark Arrestor

    4. Inspect the screen for wear and damage. Replace if needed. 5. Reinstall the arrestor and torque the retaining screw to specification. TORQUE Spark Arrestor: 8 lb-ft (11 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.20 © Copyright Polaris Industries Inc.

  • Page 59: Cooling System Maintenance

    The recovery bottle and radiator pressure cap located under the hood. 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.

  • Page 60: Cooling System Hoses

    FLUID CAPACITY Recommended Anti-Freeze/Coolant: Premium Pre-Mixed Extended Life Antifreeze (PN 2880514) (Quart) (PN 2880513) (Gallon) 9. Reinstall the recovery bottle cap. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.22 © Copyright Polaris Industries Inc.

  • Page 61: Radiator Inspection / Cleaning

    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 2.23 © Copyright Polaris Industries Inc.

  • Page 62: Fuel System And Air Intake Maintenance

    . The fuel pump must be replaced as an assembly. Refer to “Fuel Pump Replacement”page 4.18 procedure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.24 © Copyright Polaris Industries Inc.

  • Page 63: Fuel Lines

    Test”page 4.30 procedure if experiencing a lack of throttle response. 3. Be sure fuel lines are routed and retained properly. NOTICE Make sure lines are not kinked or pinched. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.25 © Copyright Polaris Industries Inc.

  • Page 64: Engine Intake Pre-Filter Screen Service

    2. Release the (5) airbox cover latches and lower the bottom cover to access the air filter element. NOTICE Make sure the hinge pins are properly seated when reassembling the airbox 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.26 © Copyright Polaris Industries Inc.

  • Page 65: Maintenance

    PLUG, DRAIN HOSE, ENGINE INTAKE HOSE, INTAKE BOOT HOSE, ENGINE VENT FENDER, INTAKE REAR HOSE, AIRBOX INTAKE DUCT, AIR INTAKE CLAMP, HOSE CLAMP, HOSE 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.27 © Copyright Polaris Industries Inc.

  • Page 66: Exhaust Heat Shield Inspection

    Inspect Exhaust Heat Shields and make sure they are in good condition and are secured properly. ITEM DESCRIPTION Close-off Bracket Chassis Shield Silencer Shield, Main 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.28 © Copyright Polaris Industries Inc.

  • Page 67: Transmission And Front Gearcase Maintenance

    Access the drain plug through the drain hole in the skid plate. 5. Remove the fill plug. 6. Place a drain pan under the transmission drain plug. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.29 © Copyright Polaris Industries Inc.

  • Page 68: Front Gearcase Lubrication

    6. Remove the fill plug. 7. Place a drain pan under the front gearcase drain plug. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.30 © Copyright Polaris Industries Inc.

  • Page 69: Pvt / Final Drive / Wheel And Tire Maintenance

    PVT system and has not been operated for a period of time, be sure to check the PVT system components for water damage. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.31 © Copyright Polaris Industries Inc.

  • Page 70: Drive Shaft Boot Inspection

    4. Elevate the appropriate side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and remove the wheel 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.32 © Copyright Polaris Industries Inc.

  • Page 71: Tire Inspection

    Worn tires can cause an accident. Always replace tires when the usable tread depth has worn out. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.33 © Copyright Polaris Industries Inc.

  • Page 72: Steering Maintenance

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

  • Page 73: Wheel Toe Alignment Inspection

    (B). • Loosen jam nuts at both end of the tie rod. MEASUREMENT Wheel Toe-Out (A) - (B): 1/8-1/4 in (3.2-6.4 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.35 © Copyright Polaris Industries Inc.
  • Page 74 Damage may not be immediately apparent if done incorrectly. • After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 13 lb-ft (18 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.36 © Copyright Polaris Industries Inc.

  • Page 75: Suspension Maintenance

    Shock Spanner Wrench: 2871095 4. Reinstall the upper shock mounting bolts and torque to specification. TORQUE Shock Mounting Bolts: 40 lb-ft (54 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.37 © Copyright Polaris Industries Inc.

  • Page 76: Brake System Maintenance

    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 2.38 © Copyright Polaris Industries Inc.

  • Page 77: Electrical And Ignition System Maintenance

    3. Coat the terminals with dielectric grease or petroleum jelly. 4. Install and tighten the red (positive) cable first. Torque to specification. TORQUE Battery Terminal Bolt: 6 lb-ft (8 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.39 © Copyright Polaris Industries Inc.

  • Page 78: Chassis / Engine Electrical Ground

    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 2.40 © Copyright Polaris Industries Inc.
  • Page 79 MAG and PTO spark plug wire decals (B). Ensure wires are pushed down all the way so they engage onto the spark plugs. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.41 © Copyright Polaris Industries Inc.
  • Page 80 MAINTENANCE NOTES 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 2.42 © Copyright Polaris Industries Inc.
  • Page 81 ..........3.47 STARTER ONE-WAY CLUTCH DISASSEMBLY 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 82 ............. 3.104 EXHAUST REMOVAL / INSTALLATION 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 83 ..............3.139 HEATER COIL REPLACEMENT 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 84 ..........3.148 ENGINE COOLANT BYPASSING THE HEATER VALVE 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 85: 900 / 1000 Engine

    • Crankshaft Seal (PTO) Bosch Automotive Service Solutions: 1-800-345-2233 • Cylinder or http://polaris.service-solutions.com/ • Oil Pump / Oil Pump Sprocket or Chain • Piston / Rings 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 86: Torque Specifications - Engine / Cooling System (900/1000)

    Step 3 (M10) Camshaft Sprocket Bolts 14 lb-ft (19 Nm) (1000) Lower Crankcase Bolts 26 lb-ft (35 Nm) (M8) Spark Plug (900/1000) 7 lb-ft (10 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 87 Coolant Bleed Screw Water Pump Mounting 7 lb-ft (10 Nm) Bolts Water Pump Impeller Bolt 7 lb-ft (10 Nm) Water Pump Cover Bolts 7 lb-ft (10 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 88: Service Specifications - Engine / Cooling System (900/1000)

    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) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 89 4.9527" ± 0.0078" (125.8 ± 0.2 mm) Bearing Journal O.D. (Standard) 1.4939" - 1.4946" (37.946 - 37.962 mm) Balance Shaft Bearing Journal O.D. (Service Limit) 1.4921" (37.900 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 90 .0590 ± .0039" (1.5 ± 0.10 mm) .0748" (1.9 mm) Valve Seat 30.0° ± 1.5° Valve Seat Angles 45.0° ± 0.5° 60.0° ± 1.5° 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.10 © Copyright Polaris Industries Inc.
  • Page 91 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.

  • Page 92: Engine Detail - Torque Values / Sequences / Assembly Notes (900 / 1000)

    ENGINE / COOLING / HVAC SYSTEM ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES (900 / 1000) MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE Cam Carrier 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.12 © Copyright Polaris Industries Inc.
  • Page 93 ENGINE / COOLING / HVAC SYSTEM Crankcase Split-Line (Bottom) Crankcase Split-Line (Top) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.13 © Copyright Polaris Industries Inc.
  • Page 94 ENGINE / COOLING / HVAC SYSTEM Cylinder Head Sump Cover 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.14 © Copyright Polaris Industries Inc.
  • Page 95 ENGINE / COOLING / HVAC SYSTEM Stator Cover 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.15 © Copyright Polaris Industries Inc.

  • Page 96: Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons

    ENGINE / COOLING / HVAC SYSTEM BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.16 © Copyright Polaris Industries Inc.

  • Page 97: Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump

    ENGINE / COOLING / HVAC SYSTEM CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.17 © Copyright Polaris Industries Inc.

  • Page 98: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

    ENGINE / COOLING / HVAC SYSTEM CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.18 © Copyright Polaris Industries Inc.

  • Page 99: Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover

    ENGINE / COOLING / HVAC SYSTEM SPARK PLUGS / STARTER / THERMOSTAT HOUSING / THROTTLE BODY / VALVE COVER 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.19 © Copyright Polaris Industries Inc.

  • Page 100: Engine Service (900 / 1000)

    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 3.20 © Copyright Polaris Industries Inc.
  • Page 101 11. Remove the spark plug wires from the engine. NOTICE The spark plug wires are marked with MAG and PTO. Note during installation procedure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.21 © Copyright Polaris Industries Inc.
  • Page 102 17. Using a 15mm socket, remove the four fasteners (P) securing the front of the engine to the mount bracket. 18. Remove the crankcase breather hose (Q) from the engine. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.22 © Copyright Polaris Industries Inc.
  • Page 103 23. Remove the six transmission joint bracket bolts and transmission joint bracket from the engine. 24. Install the engine stand adapter (PU-50562) onto the engine where the starter motor was located. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.23 © Copyright Polaris Industries Inc.

  • Page 104: Engine Installation

    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. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.24 © Copyright Polaris Industries Inc.
  • Page 105 Step 1-2: 64 lb-ft (87 Nm) Step 3: 5 lb-ft (7 Nm) Step 4-7: 44 lb-ft (60 Nm) 12. Remove the clutch center distance tool. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.25 © Copyright Polaris Industries Inc.
  • Page 106 (I). NOTICE Be sure the intake plenum runners are fully seated in the intake adapters before tightening the hose clamps. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.26 © Copyright Polaris Industries Inc.
  • Page 107 Refer to Engine Oil and Filter Changepage 2.15 procedure. 36. Add approximately 2.5 quarts (3.3 L) of Polaris PS-4 or PS-4 Extreme Duty Synthetic Engine Oil to the engine. Additional oil may be required after complete engine disassembly.

  • Page 108: Engine Break-In Period

    CAUTION Use only Polaris PS-4 or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil.Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result. Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

  • Page 109: Oil Pressure Test

    NOTICE Test results are based on the use of the recommended engine oil (Polaris PS-4 or PS-4 Extreme Duty) at operating temperature, and may vary considerably if any other oil is used or if engine is not up to temperature.

  • Page 110: Engine Oil Flow Chart

    ENGINE / COOLING / HVAC SYSTEM ENGINE OIL FLOW CHART 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.30 © Copyright Polaris Industries Inc.

  • Page 111: Engine Disassembly / Inspection - Top End (900 / 1000)

    3. Remove the spark plugs . Stuff spark plug holes with shop towels to prevent anything from falling into the combustion chamber. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.31 © Copyright Polaris Industries Inc.
  • Page 112 12. Carefully remove camshafts from the cylinder head. 7. Remove the remaining bolts from each camshaft sprocket 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.32 © Copyright Polaris Industries Inc.

  • Page 113: Camshaft Sprocket Inspection

    Exhaust: 1.4961" ± .0015" (38.00 ± .040 mm) Service Limit: 1.4925" (37.91 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.33 © Copyright Polaris Industries Inc.
  • Page 114 Calculated Camshaft Oil Clearance: 0.0009" - 0.0028" (.022 - .072 mm) Service Limit: 0.0039" (.10 mm) TORQUE Camshaft Carrier Bolts: 7 lb-ft (10 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.34 © Copyright Polaris Industries Inc.

  • Page 115: Camshaft / Camshaft Bore Inspection (1000)

    Service Limit: 1.5122" (38.41 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. TORQUE Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.35 © Copyright Polaris Industries Inc.

  • Page 116: Cylinder Head Removal

    3. Loosen the six cylinder head bolts (C) evenly 1/8 turn Plate (PU-50563). Refer to “Cylinder / Piston at a time until all are loose. Removal”page 3.55 procedure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.36 © Copyright Polaris Industries Inc.

  • Page 117: Cylinder Head Inspection

    2. Compress the valve spring by hand using valve spring compressor adapter (PV-43513-A). MEASUREMENT Cylinder Head Warp Limit: .0039" (0.10 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.37 © Copyright Polaris Industries Inc.

  • Page 118: Valve Inspection

    8. Clean the combustion chamber and head gasket surface. 3. Check the end of the valve stem for flaring, pitting, wear or damage. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.38 © Copyright Polaris Industries Inc.

  • Page 119: Combustion Chamber Cleaning

    Pay close attention to areas around spark plug and valve seats. MEASUREMENT Valve Guide I.D.: 0.2165" - 0.2171" (5.500 - 5.515 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.39 © Copyright Polaris Industries Inc.

  • Page 120: Valve Sealing Test

    1. Install pilot into valve guide. 2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.40 © Copyright Polaris Industries Inc.
  • Page 121 (A). black permanent marker to the entire valve face (A). 6. Insert valve into guide and tap valve lightly into place a few times. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.41 © Copyright Polaris Industries Inc.

  • Page 122: Valve Seat Reconditioning (1000)

    3. Place 46° cutter on the pilot and make a light cut. connected to the valve stem. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.42 © Copyright Polaris Industries Inc.
  • Page 123 6. Insert valve into guide and tap valve lightly into place a few times. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.43 © Copyright Polaris Industries Inc.
  • Page 124 12. Thoroughly clean cylinder head and valves. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.44 © Copyright Polaris Industries Inc.

  • Page 125: Engine Disassembly / Inspection - Lower End (900 / 1000)

    3. Inspect the condition of the stator windings (A) and result. output wires (B). Replace if necessary. 4. Inspect the ball bearing (C) that supports the starter motor shaft. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.45 © Copyright Polaris Industries Inc.

  • Page 126: Water Pump Housing Removal

    Inspect the shaft and bearing surfaces in the crankcase and stator cover for excessive wear. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.46 © Copyright Polaris Industries Inc.

  • Page 127: Starter One-Way Clutch Disassembly

    Grasp clutch gear and rotate clockwise. It should turn smoothly without binding. 9. Rotate one-way gear counterclockwise. The gear should immediately lock in position and not slip. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.47 © Copyright Polaris Industries Inc.

  • Page 128: Crankcase Disassembly / Inspection

    3. Remove the oil filter. 4. Remove the water inlet cover (C) from the cylinder. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.48 © Copyright Polaris Industries Inc.
  • Page 129 Access the sprocket bolt by removing the case plug. 9. Remove and clean oil pump pick-up (E). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.49 © Copyright Polaris Industries Inc.
  • Page 130 Carefully lift up and remove the lower crankcase half. NOTICE Oil pump assembly is non-serviceable 14. Rotate the engine so the cylinder is facing up. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.50 © Copyright Polaris Industries Inc.

  • Page 131: Balance Shaft Removal / Inspection

    1.4939" - 1.4946" (37.946 - 37.962 mm) from the crankcase. Service Limit: 1.4921" (37.900 mm) 4. Inspect the balance shaft gear teeth for damage. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.51 © Copyright Polaris Industries Inc.

  • Page 132: Crankshaft Removal / Inspection

    5. Carefully lift the crankshaft (N) out of the crankcase. 8. If the crankshaft gear (S) is damaged, the crankshaft assembly must be replaced. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.52 © Copyright Polaris Industries Inc.
  • Page 133 .001 in. (0.025 mm) 11. Visually inspect surface of crankshaft main and connecting rod journals. Replace crankshaft if any journal is scratched or pitted. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.53 © Copyright Polaris Industries Inc.
  • Page 134 15. Whether installing a new crankshaft or re-installing the original, refer to the bearing selection chart provided “Crankshaft Main Bearing Selection”page 3.65 “Connecting Bearing Selection”page 3.65 procedures. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.54 © Copyright Polaris Industries Inc.

  • Page 135: Crankcase Inspection

    1. Perform “ENGINE DISASSEMBLY / INSPECTION - TOP END” and the “ENGINE DISASSEMBLY / INSPECTION - LOWER END” procedures. 2. Rotate the engine so the cylinder is facing up. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.55 © Copyright Polaris Industries Inc.

  • Page 136: Cylinder Inspection

    If the pistons are to be reused, mark the pistons so they are reassembled in the same cylinder bore and direction from which they were removed (MAG / PTO). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.56 © Copyright Polaris Industries Inc.

  • Page 137: Piston Disassembly / Inspection (900)

    3.6614" ± .0003" (93 mm ± .008 mm) CAUTION DO NOT apply heat to piston rings or a loss of radial tension could result. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.57 © Copyright Polaris Industries Inc.

  • Page 138: Piston Disassembly / Inspection (1000)

    DO NOT apply heat to piston rings or a loss of radial Piston Pin O.D.: tension could result. 0.7872" - 0.7874" (19.995 - 20.000 mm) Service Limit: 0.7866" (19.98 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.58 © Copyright Polaris Industries Inc.

  • Page 139: Piston Ring Removal

    Remove top rail first, then bottom rail, then the expander. MEASUREMENT Piston Pin O.D.: .7873 - .7875" (20.000 - 20.005 mm) Service Limit: .7866" (19.98 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.59 © Copyright Polaris Industries Inc.

  • Page 140: Piston Ring To Groove Clearance Inspection

    .0007 - .0023" (0.020 - 0.060 mm) Second Ring: 0.0012" - 0.0030" (0.030 - 0.076 mm) Service Limit: Service Limit: 0.0047" (0.12 mm) .0047" (0.12 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.60 © Copyright Polaris Industries Inc.

  • Page 141: Piston Ring Installed Gap (900)

    Always check piston ring installed gap when installing new rings and/or a new cylinder. NOTICE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.61 © Copyright Polaris Industries Inc.

  • Page 142: Piston-To-Cylinder Clearance (900)

    3.6597 ± .0003" (92.959 ± 0.008 mm) Piston to Cylinder Clearance: MEASUREMENT .0009 - .0019" (0.025 - 0.050 mm) Piston to Cylinder Clearance: .0014" - .0026" (.035 - .065 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.62 © Copyright Polaris Industries Inc.

  • Page 143: Connecting Rod Inspection

    Nm) prior to taking any measurements. 5. Using a dial bore gauge, measure big end I.D. in two directions shown. Record measurements compare to specifications. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.63 © Copyright Polaris Industries Inc.

  • Page 144: Engine Assembly - Lower End (900 / 1000)

    *Some engines may only have 4 digits. The extra two digits will refer to the balance shaft bearings which should now all be standard. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.64 © Copyright Polaris Industries Inc.

  • Page 145: Connecting Rod Bearing Selection

    Bearing Selection Chart — Main Bearings Blue Green Yellow Crankshaft Green Yellow Yellow Code Blue Blue Green Case Blue Green Yellow Green Yellow Yellow 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.65 © Copyright Polaris Industries Inc.

  • Page 146: Upper Crankcase Preparation

    NOTICE Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.66 © Copyright Polaris Industries Inc.
  • Page 147 6. Be sure top and second rings rotate freely in their side of piston as shown below. grooves and do not bind when compressed by hand. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.67 © Copyright Polaris Industries Inc.

  • Page 148: Piston / Connecting Rod Assembly

    (there is no piston pin offset in the rod), however it is recommended they be installed with rods facing the same direction. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.68 © Copyright Polaris Industries Inc.

  • Page 149: Cylinder / Piston Installation

    10. Carefully place the cylinder and pistons into the upper crankcase. NOTICE Orientation arrow is also located on the bottom side of piston as an additional reference. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.69 © Copyright Polaris Industries Inc.

  • Page 150: Crankshaft Installation (900)

    5. Install oil drain diverter (C) into the upper crankcase. (PU-50563) onto the cylinder. The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 6. Apply Polaris PS-4 engine oil to each main and rod bearing journal of crankshaft. CRANKSHAFT INSTALLATION (900) IMPORTANT Whether installing a new crankshaft or re-installing the original, refer to the bearing selection charts.

  • Page 151: Crankshaft Installation (1000)

    14. Torque connecting rod bolts to specification. TORQUE Connecting Rod Bolts: Step 1: 9 lb-ft (12 Nm) Step 2: 22 lb-ft (30 Nm) Step 3: Additional 90° 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.71 © Copyright Polaris Industries Inc.
  • Page 152 ENGINE / COOLING / HVAC SYSTEM 6. Apply Polaris PS-4 engine oil to each rod bearing 11. Clean bolt hole threads in connecting rod to remove journal and main bearing journal of crankshaft. all oil. 12. Install matching rod cap on connecting rod with 3 digit serial number stampings aligned &...

  • Page 153: Balance Shaft Installation

    3. Rotate the crankshaft until the alignment dot (B) on the crankshaft MAG end gear is visible. 4. Apply Polaris PS-4 engine oil to both balance shaft journals. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.73...

  • Page 154: Lower Crankcase Preparation

    8. Inspect crankcase mating surfaces to be sure they are joined properly. Investigate the cause of any 3. Apply Polaris PS-4 engine oil to the new bearings gaps. installed in the lower crankcase half. 4. Clean crankcase mating surfaces to remove any oil.
  • Page 155 Step 3: Additional 90° M8 Bolts: 26 lb-ft (35 Nm) M6 Bolts: 9 lb-ft (12 Nm) 11. Rotate the engine so the cylinder is facing up. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.75 © Copyright Polaris Industries Inc.
  • Page 156 Dipstick must be removed before oil pan is assembled to the engine. Failure to do this will damage the dipstick. TORQUE Oil Pump Mounting Bolts: 7 lb-ft (10 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.76 © Copyright Polaris Industries Inc.
  • Page 157 26. Rotate the engine so the cylinder is facing up. 27. Reinstall the oil cooler (J), if previously removed. Use new O-rings upon installation. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.77 © Copyright Polaris Industries Inc.

  • Page 158: Starter One-Way Clutch Assembly

    One-Way Clutch Retaining Screws are one time use. NEW screws must be used when installing the one-way clutch. TORQUE One-Way Clutch Retaining Screws: 9 lb-ft (12 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.78 © Copyright Polaris Industries Inc.

  • Page 159: Flywheel Installation

    If the Cylinder Holding & Camshaft Timing Plate (PU- 50563) is installed, remove it before tightening the flywheel. TORQUE Flywheel Retaining Bolt: 133 lb-ft (180 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.79 © Copyright Polaris Industries Inc.

  • Page 160: Stator Cover Installation

    / installation process or injury could result. 3. Install stator cover and thirteen screws. Torque screws in sequence to specification. TORQUE Stator Cover Screws: 9 lb-ft (12 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.80 © Copyright Polaris Industries Inc.

  • Page 161: Engine Assembly - Top End (900 / 1000)

    Valve seals should be installed AFTER the valves are in the head to avoid valve seal damage. 5. Dip the valve spring (C) and retainer (D) in clean engine oil. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.81 © Copyright Polaris Industries Inc.

  • Page 162: Valve Sealing Test

    Clearance Adjustment”page 3.93 for proper shim selection. If any valve train components were replaced, refer to “Valve Clearance Adjustment”page 3.93 procedure prior “Camshaft Installation Timing”page 3.84 procedure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.82 © Copyright Polaris Industries Inc.

  • Page 163: Cylinder Head Installation

    5. Carefully set the cylinder head (F) in place on alignment pins. 6. Install new bolts and finger tighten the six cylinder IMPORTANT head bolts (G) evenly. Install new cylinder head bolts. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.83 © Copyright Polaris Industries Inc.

  • Page 164: Camshaft Installation / Timing (900)

    Intake Camshaft PN: 1204583 Exhaust Camshaft PN: 1204584 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.84 © Copyright Polaris Industries Inc.
  • Page 165 ENGINE / COOLING / HVAC SYSTEM 3. Lubricate all camshaft lobes and bearing journal 7. Install the Cylinder Holding & Camshaft Timing Plate surfaces with Polaris PS-4 engine oil prior to (PU-50563) into the end of camshafts as shown. Use installation.
  • Page 166 (see Step 1) and cam sprocket sprocket. Do not torque the bolts at this time. markings should line up as shown. IMPORTANT Use NEW sprocket retaining bolts upon assembly. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.86 © Copyright Polaris Industries Inc.
  • Page 167 15. Remove the Cylinder Holding & Camshaft Timing Plate (PU-50563) from the end of the camshafts. 16. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. 17. Retract the plunger all the way in and install into the cylinder.
  • Page 168 ENGINE / COOLING / HVAC SYSTEM 26. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.88 © Copyright Polaris Industries Inc.

  • Page 169: Camshaft Installation / Timing (1000)

    7. Install the Cylinder Holding & Camshaft Timing Plate 3. Lubricate all camshaft lobes and bearing journal (PU-50563) into the end of camshafts as shown. Use surfaces with Polaris PS-4 engine oil prior to a 13/16” open-end wrench to rotate camshafts installation.
  • Page 170 Install the top bolt in each camshaft sprocket . Do not torque the bolts at this time. IMPORTANT Use NEW sprocket retaining bolts upon assembly. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.90 © Copyright Polaris Industries Inc.
  • Page 171 TORQUE Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 21. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. Use a new tensioner sealing washer 22. Install the hydraulic cam chain tensioner into the cylinder and torque to specification.

  • Page 172: Camshaft Timing - Quick Reference

    ENGINE / COOLING / HVAC SYSTEM CAMSHAFT TIMING - QUICK REFERENCE 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.92 © Copyright Polaris Industries Inc.

  • Page 173: Valve Clearance Adjustment

    Intake Camshaft PN: 1204583 Exhaust Camshaft PN: 1204584 2. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 3. Carefully install the camshafts into the cylinder head. The PTO camshaft lobes should face out as shown.
  • Page 174 18. If valve clearance is not within specification, repeat this procedure. 19. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to “Camshaft Installation / Timing”. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.94 © Copyright Polaris Industries Inc.

  • Page 175: Valve Cover Installation

    5. Replace the isolators (C) around each T40 bolt. 6. Install the four valve cover shoulder bolts (D) and isolators (C) using a T40 driver. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.95 © Copyright Polaris Industries Inc.

  • Page 176: Valve Lash - Tappet Selection

    5. Refer to the table below to find the closest available tappet size to the result from step 4 (i. e. 459 should be rounded to 460 since there is a 460 tappet). Available Tappets 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.96 © Copyright Polaris Industries Inc.

  • Page 177: Intake / Exhaust Service (900 / 1000)

    7. Remove the clamp holding the intake duct to the LH upper fender. 4. Remove the fasteners holding the air box assembly to the frame of the vehicle. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.97 © Copyright Polaris Industries Inc.

  • Page 178: Intake Installation

    Torque the clamp to specification. TORQUE TORQUE Air Box Fasteners: Intake Duct Clamps: 8 lb-ft (11 Nm) 17 lb-in (2 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.98 © Copyright Polaris Industries Inc.
  • Page 179 Torque clamp to specification. TORQUE Intake Duct Clamps: 17 lb-in (2 Nm) 7. Lower the cargo box and secure in position. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.99 © Copyright Polaris Industries Inc.

  • Page 180: Intake Manifold Removal

    8. Remove the Fuel Line by pulling open the connector while moving the connector out to release the line. IMPORTANT Place a shop towel around the fuel line to catch any dripping fuel. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.100 © Copyright Polaris Industries Inc.
  • Page 181 Make note of Hose Clamps orientation for installation. 10. Loosen Intake Manifold Mounting Bolt located at the transmission bracket. 11. Remove Intake Manifold from engine. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.101 © Copyright Polaris Industries Inc.

  • Page 182: Intake Manifold Installation

    6. Install electrical harness to engine and plug in Fuel place. Verify the connector tabs snap back into place Injectors , TMAP sensor and Throttle Body by pulling out lightly on connector. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.102 © Copyright Polaris Industries Inc.
  • Page 183 12. Perform ETC Learn Procedurepage 4.24, connecting battery as needed. 13. Inspect engine while running to watch for any fuel leaks. 14. Perform Cargo Box Installationpage 10.27. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.103 © Copyright Polaris Industries Inc.

  • Page 184: Exhaust Removal / Installation

    8. To reinstall the exhaust system, reverse the removal steps. IMPORTANT Install NEW exhaust gaskets and torque all hardware to specification. TORQUE Headpipe Mounting Bolts: 18 lb-ft (24 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.104 © Copyright Polaris Industries Inc.

  • Page 185: Cooling System Service (900 / 1000)

    ENGINE / COOLING / HVAC SYSTEM COOLING SYSTEM SERVICE (900 / 1000) COOLING SYSTEM EXPLODED VIEW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.105 © Copyright Polaris Industries Inc.

  • Page 186: Water Pump Exploded View

    ENGINE / COOLING / HVAC SYSTEM WATER PUMP EXPLODED VIEW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.106 © Copyright Polaris Industries Inc.

  • Page 187: Cooling System Specifications

    3. Replace cap if it does not meet the specification. reduce heat dissipation, resulting in possible engine damage. Polaris Premium 50/50 Extended Life Radiator Cap Relief Pressure Antifreeze is recommended for use in all cooling 13 psi (90 kPa) systems and comes pre-mixed, ready to use.

  • Page 188: Radiator Fan Removal

    9. Lift up on the flexible portion of the hood liner to access the upper radiator hose and remove the hose from the radiator. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.108 © Copyright Polaris Industries Inc.

  • Page 189: Thermostat Replacement

    7. Remove the thermostat cover , seal thermostat from the engine. NOTICE Thermostat has a pop-off relief to allow the bypass system to operate until thermostat opens. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.109 © Copyright Polaris Industries Inc.

  • Page 190: Cooling System Bleeding Procedure

    8. Clean thermostat mating surfaces on the engine and 4. Remove the pressure cap and add the necessary thermostat cover. amount of Polaris Premium Antifreeze to the radiator filler neck. 9. Install a new thermostat and seal into the cover and install the cover onto engine.

  • Page 191: Water Pump Removal

    12. Plug the water pump drive access hole in the engine block with a clean shop towel. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.111 © Copyright Polaris Industries Inc.
  • Page 192 Be sure orientation and routing are correct. 12. Install the exhaust system as outlined in this chapter. 13. Connect the (-) negative battery cable. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.112 © Copyright Polaris Industries Inc.

  • Page 193: Water Pump Service

    5. Remove impeller from water pump shaft. 6. Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.113 © Copyright Polaris Industries Inc.
  • Page 194 22. Install water pump assembly into engine as shown in 19. Install a new water pump cover gasket. the “Water Pump Installation” procedure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.114 © Copyright Polaris Industries Inc.

  • Page 195: Troubleshooting - Engine / Cooling System

    • Restricted fuel supply • Loose Electrical connections • Low compression • Decompression Mechanism not functioning properly. • Crankcase breather restricted Engine Idles But Will Not Accelerate 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.115 © Copyright Polaris Industries Inc.

  • Page 196: Cooling System Troubleshooting

    • Thermostat stuck open Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.116 © Copyright Polaris Industries Inc.

  • Page 197: Hvac System

    Expansion Valve High / Low 12 ft-lb (16 Nm) Pressure Hoses Expansion Valve Tubes 22 ft-lb (30 Nm) 8 lb-ft (11 Nm) Heater Valve Fasteners 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.117 © Copyright Polaris Industries Inc.

  • Page 198: Hvac System Overview

    The Electronic De-icing Thermostat is a micro controller based module that measures evaporator coil temperature and cycles the compressor clutch to maintain a constant evaporator pressure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.118 © Copyright Polaris Industries Inc.

  • Page 199: Hvac Assembly View

    Electronic De-icing Thermostat (EDT) A/C Charge Port Heater Valve High Pressure Cut-Out Switch (HPCO) Compressor Drive Belt Alternator Alternator Cover Alternator Air Inlet Alternator Air Outlet 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.119 © Copyright Polaris Industries Inc.

  • Page 200: A/C System Diagram

    ENGINE / COOLING / HVAC SYSTEM A/C SYSTEM DIAGRAM 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.120 © Copyright Polaris Industries Inc.

  • Page 201: Safety Equipment

    This small brass valve is a safety feature that is designed to open and release the A/C charge if the pressure reaches 535 psi (3.7 MPa). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.121 © Copyright Polaris Industries Inc.
  • Page 202 Heater Valve from fully Off to fully On. This can be used the temperature of the evaporator coil. in conjunction with the A/C for defrost of the windows and temperature control. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.122 © Copyright Polaris Industries Inc.
  • Page 203 400 psi. (2.8 MPa) and will engage the clutch when pressures lower to 325 psi (2.2 MPa). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.123 © Copyright Polaris Industries Inc.

  • Page 204: Hvac Maintenance

    ALWAYS use the specified drive belt. Using a non- specified belt can shorten the belt life. 4. Reinstall the grass screen and turn the two 1/4 turn fasteners clockwise. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.124 © Copyright Polaris Industries Inc.

  • Page 205: Hvac Filter Inspection / Replacement

    System Capacity: R134a 1.8 lbs (.816 kg) 2. Remove the hood and the cabin air filter. 3. Clean the filter with low air pressure. Check for damage, replace if damaged. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.125 © Copyright Polaris Industries Inc.

  • Page 206: Reclamation And Charging With Recovery / Charging Unit

    2. Use an approved recovery / charging unit to evacuate the system. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.126 © Copyright Polaris Industries Inc.

  • Page 207: Hvac System Service

    6. Loosen the three alternator fasteners enough to slide the alternator outward with enough room for the compressor drive belt to slide belt. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.127 © Copyright Polaris Industries Inc.
  • Page 208 14. Install the inner alternator cover and torque the fasteners to specification. Reconnect the alternator air outlet hose. TORQUE Alternator Cover Fasteners: 48 lb-in (5.4 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.128 © Copyright Polaris Industries Inc.

  • Page 209: Compressor Replacement

    37 lb-ft (50 Nm) 9. Recharge the A/C system. 4. Remove the low pressure hose from the compressor. 5. Remove the high pressure hose from the compressor. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.129 © Copyright Polaris Industries Inc.

  • Page 210: Compressor Oil Specifications

    IMPORTANT Only PAG 100 oil should be used. Never mix R-12 and R-134a Oils. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.130 © Copyright Polaris Industries Inc.

  • Page 211: Alternator Inspection

    . Add 150 - 170 cc's of PAG 100 oil. NOTICE The suction port on the compressor is marked with an S and is the larger. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.131 © Copyright Polaris Industries Inc.

  • Page 212: Alternator Replacement

    5. For installation, reverse removal procedure. 6. Torque the alternator fasteners to specification in the sequence as shown. TORQUE Alternator Mounting Fasteners: 37 lb-ft (50 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.132 © Copyright Polaris Industries Inc.

  • Page 213: Hvac Cover Mount Replacement

    10. Torque the drive pulley fastener to specification using Crankshaft Pulley Holder PU-52254. TORQUE HVAC Drive Pulley Fastener: 44 lb-ft (60 Nm) + 180° 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.133 © Copyright Polaris Industries Inc.

  • Page 214: Condenser Replacement

    12 ft-lb (16 Nm) Condenser Upper Mounting Bolt: 14 ft-lb (19 Nm) Condenser Lower Mounting Bolts: 8 ft-lb (11 Nm) 11. Recharge A/C system. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.134 © Copyright Polaris Industries Inc.

  • Page 215: Receiver / Drier Replacement

    / drier. 5. Cap and plug the hoses and the receiver / drier fittings with the proper A/C caps and plugs. 6. Remove the bolts 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.135 © Copyright Polaris Industries Inc.

  • Page 216: Pressure Relief Valve Replacement

    Replacement of the high pressure cut out switch does NOT require discharging/recharging the R-134a 4. Disconnect the blower unit connector to the wire refrigerant. harness. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.136 © Copyright Polaris Industries Inc.

  • Page 217: Expansion Valve / Evaporator Coil Replacement

    Refer to Heater / Evaporator Unit Replacement procedure. 3. Remove the fasteners holding the expansion valve to the heater / evaporator unit bottom cover. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.137 © Copyright Polaris Industries Inc.
  • Page 218 7. To Install, reverse procedure. Tighten fasteners to specification. TORQUE Expansion Valve Pressure Hoses: 12 ft-lb (16 Nm) Expansion Valve Tubes: 22 ft-lb (30 Nm) 8. Recharge the A/C system. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.138 © Copyright Polaris Industries Inc.

  • Page 219: Heater Coil Replacement

    When the EDT detects an error from the temperature unit. Refer to “Heater Coil Replacement”page sensor, the status LED will blink. Refer to the chart 3.139 procedure. below. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.139 © Copyright Polaris Industries Inc.

  • Page 220: Heater Valve Replacement

    3. Remove the hose clamps and coolant hoses from System Bleeding Procedurepage the heater valve. NOTICE Plug the hoses to prevent contamination and coolant loss from the system. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.140 © Copyright Polaris Industries Inc.

  • Page 221: Hvac Control Service

    The fan switch controls the blower fan speed. The fan switch can be tested using an ohmmeter. 1. Disconnect the harness going to the Fan Switch. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.141 © Copyright Polaris Industries Inc.

  • Page 222: Hvac Breakout Diagram

    ENGINE / COOLING / HVAC SYSTEM HVAC BREAKOUT DIAGRAM 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.142 © Copyright Polaris Industries Inc.

  • Page 223: Troubleshooting - Hvac

    3. Defective thermostat. Check thermostat using a circuit tester. Replace thermostat switch (frozen evaporator) 4. Plugged cab filters Clean or replace filters Check cab filter condition. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.143 © Copyright Polaris Industries Inc.

  • Page 224: Insufficient Cooling (Air Flow And Compressor Operation Are Normal)

    • If power is present replace the HP switch. • If there is no Power at the HP switch, measure the Pin A wire to the thermostat Pin 1 white wire. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.144 © Copyright Polaris Industries Inc.
  • Page 225 Clutch will not engage. Inspect the ground and Repair. ground. connections. 8. Wiring harness Test the conductance of the pressure switch, Check operation. components. thermostat, Relay, etc. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.145 © Copyright Polaris Industries Inc.

  • Page 226: Gauge Pressure Related Troubleshooting

    System pressures equal 1. Clutch not operating. See compressor clutch related topics above. 2. Compressor not Equal high and low pressures. Replace compressor. pumping. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.146 © Copyright Polaris Industries Inc.

  • Page 227: Temperature / Pressure Chart

    Example: Ambient Temperature = 90ºF 90ºF + 40ºF = 130ºF condenser temperature / 200 PSIG Conditions and pressures will vary from system to system. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.147 © Copyright Polaris Industries Inc.

  • Page 228: Poor A/C Performance

    High A/C position. 8. Replace the heater valve. 2. Start the utility vehicle and run at high idle, for ten minutes. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 3.148 © Copyright Polaris Industries Inc.
  • Page 229 ..............4.27 T-MAP SENSOR REPLACEMENT 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 230 ............4.50 POLARIS MOBILE DIGITAL WRENCH (PMDW) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual ©...

  • Page 231: General Information - Fuel System

    • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 232: Special Tools - Fuel System

    USB to serial port adapter will be necessary. A USB to serial port adapter can be purchased through Bosch Automotive Service Solutions (PU-50621) or DSA at: www.diagsys.com 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 233: Service Specifications - Fuel System

    SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This module kit is used on all 8 pin connector-based Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.

  • Page 234: Electronic Fuel Injection

    During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically calculated by the ECU. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 235: Fuel System Components

    • Temp / Manifold Absolute Pressure Sensor (T-MAP) • Wire Harness Assembly 3. Crankshaft Position Sensor (CPS) - Located on top of the stator cover. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 236 - Located on the side of the throttle pedal assembly - Connected to the left end of the fuel rail and top of (cover removed). the fuel pump. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 237 10. Fuel Pump / Regulator / Fuel Level Sender Assembly - Located under the driver’s seat. 11. Ignition Coil / High Tension Leads - Located next to the airbox behind the driver’s seat. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 238: Fuel Lines

    NOTICE Image orientation is from the rear driver-side of the vehicle with the cargo box in the raised position. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.10 © Copyright Polaris Industries Inc.

  • Page 239: Fuel Line Removal / Installation

    Fuel Line Routingpage 4.10. 3. Disconnect the fuel line connector securing the fuel line to the electrical harness. 4. Pull the fuel line outward to remove. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.11 © Copyright Polaris Industries Inc.

  • Page 240: Fuel Vent Line Routing

    The vent line is secured along the middle section of the line NOTICE Image orientation is from the rear passenger-side of the vehicle. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.12 © Copyright Polaris Industries Inc.

  • Page 241: Fuel Tank Service

    Tank Vent / Rollover Valve Fuel Fill Hose Fuel Sender Nut Fuel Inlet Fuel Pump / Regulator Fuel Cap Fuel Level Float Arm Preliminary Fuel Filter Gasket 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.13 © Copyright Polaris Industries Inc.

  • Page 242: Fuel Line Removal / Installation

    6. Be sure fuel line is routed and retained properly. 5. Remove the fuel tank vent line (C) from the tank fitting. 6. Disconnect the fuel pump electrical harness (B). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.14 © Copyright Polaris Industries Inc.

  • Page 243: Fuel Tank Installation

    8. Install storage bins and driver and passenger seat bases. 9. Slide the fuel tank toward front of vehicle and remove the tank from vehicle. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.15 © Copyright Polaris Industries Inc.

  • Page 244: Fuel Pump Service

    6. If none of the conditions exist, the fuel sender assembly is faulty. Replace the fuel pump assembly. Refer to Fuel Pump Replacement procedure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.16 © Copyright Polaris Industries Inc.

  • Page 245: Fuel Pump Test

    NOTICE If there was no continuity between the pump terminals, replace the fuel pump assembly. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.17 © Copyright Polaris Industries Inc.

  • Page 246: Fuel Pump Replacement

    4. Ensure that static has been discharged by touching a ground source such as the engine or frame. NOTICE Apply downward force on the fuel pump flange while removing the fuel pump nut. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.18 © Copyright Polaris Industries Inc.
  • Page 247 19. Torque nut to specification using the Fuel Pump Service Tool (PU-50326) and a calibrated torque wrench. TORQUE Fuel Pump Nut: 70 lb-ft (95 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.19 © Copyright Polaris Industries Inc.
  • Page 248 23. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times to prime the system. 24. Install storage bin and driver’s seat base. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.20 © Copyright Polaris Industries Inc.

  • Page 249: Electronic Control Unit (Ecu)

    (on/off), intake air temperature, manifold performed. If a problem is encountered, and you absolute pressure (load), engine coolant temperature, determine the ECU to be faulty, contact the Polaris crankshaft position and engine speed (RPM), throttle Service Department for specific handling instructions. Do pedal position and battery voltage.

  • Page 250: Ecu Replacement

    Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. TORQUE ECU Retaining Screws: 24 lb-in (2.7 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.22 © Copyright Polaris Industries Inc.

  • Page 251: Electronic Throttle Control (Etc)

    No internal servicing or adjustments may be performed. If a problem is encountered, and you determine the ETC to be faulty, contact the Polaris Service Department for specific handling instructions. Do 6. Reverse these steps for installation. Torque the ETC not replace the ETC without factory authorization.

  • Page 252: Etc Learn Procedure

    3. Turn key back on and start the vehicle. The vehicle should operate normally. 4. If the procedure was interrupted at any time, start back at step 1. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.24 © Copyright Polaris Industries Inc.

  • Page 253: Crankshaft Position Sensor (Cps)

    CPS and flywheel encoder ring for damage. Refer to “CPS Replacement”page 4.26 procedure. 4. If the resistance is incorrect, follow the “CPS Replacement”page 4.26 procedure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.25 © Copyright Polaris Industries Inc.

  • Page 254: Cps Replacement

    6. Torque CPS retaining bolt to specification. TORQUE CPS Retaining Bolt: 9 lb-ft (12 Nm) 7. Route CPS wire lead through wire clip and reconnect CPS harness connector. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.26 © Copyright Polaris Industries Inc.

  • Page 255: Temp / Manifold Absolute Pressure Sensor (T-Map)

    7 lb-ft (10 Nm) IMPORTANT This sensor should only be tested using the Digital Wrench® Diagnostic Software (dealer only). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.27 © Copyright Polaris Industries Inc.

  • Page 256: Engine Coolant Temperature Sensor (Ect)

    Refer to “Coolant Temperature Sensor”page 11.25 for relayed to the ECU. This signal is processed by the ECU additional ECT sensor information. Polaris dealers can and compared to its programming for determining the test the sensor by using Digital Wrench® Diagnostic fuel and ignition requirements during operation.

  • Page 257: Ect Sensor Replacement

    8. Reconnect the fuel line to the fuel rail. 9. Add the required amount of coolant and bleed the system. Refer to “Cooling System Bleeding Procedure”page 3.110. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.29 © Copyright Polaris Industries Inc.

  • Page 258: Pedal Position Sensor (Pps)

    2.1 V The Pedal Position Sensor is calibrated to the throttle pedal. If the PPS is faulty, the throttle pedal assembly must be replaced. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.30 © Copyright Polaris Industries Inc.

  • Page 259: Fuel Injector Service

    Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.31 © Copyright Polaris Industries Inc.

  • Page 260: Fuel Injector Test

    Line Removal / Installation”page 4.14 procedure. 7. Disconnect the fuel injector harness leads. 8. Remove the two screws that mount the fuel rail to the intake plenum. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.32 © Copyright Polaris Industries Inc.
  • Page 261 19. Turn the key to the on position and wait for fuel pump to prime the fuel system. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.33 © Copyright Polaris Industries Inc.

  • Page 262: Oxygen Sensor

    O2 sensor (increases the delay). The delay time ensures the oxygen sensor heater has run long enough to provide accurate data. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.34 © Copyright Polaris Industries Inc.

  • Page 263: Fuel System Diagnosis

    MODE button or turn the ignition key OFF once the 2. Press and hold the MODE button to enter the codes are recorded. diagnostics code menu. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.35 © Copyright Polaris Industries Inc.
  • Page 264 P0265 Driver Circuit Grounded P1265 Driver Circuit Open / Grounded P1691 Rear Differential Output Driver Circuit Short to B+ P1692 Driver Circuit Grounded P1693 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.36 © Copyright Polaris Industries Inc.
  • Page 265 EPS Inverter Temperature 520225 Greater than 120° C (248° F) C1055 EPS CAN Communications No RX Message for 2 Seconds 520226 U0100 Receive Error 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.37 © Copyright Polaris Industries Inc.
  • Page 266 Cut Off (Level 2) Controller Option Setting Not Out of Calibration 520290 P1544 Programmed Throttle Body Control - Requested Throttle Angle Not Condition Exists 520305 P1530 Plausible 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.38 © Copyright Polaris Industries Inc.
  • Page 267 Voltage Above Normal, or Shorted P153A to High Source Drive Model Select Switch 524067 Voltage Below Normal, or Shorted P153B to Low Source Condition Exists P1550 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.39 © Copyright Polaris Industries Inc.

  • Page 268: Cylinder Misfire Detection

    • Low battery voltage (loose connection, low charge, bad battery) • Faulty voltage regulator • Ignition Coil and connections are good • Spark plugs wires are secure 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.40 © Copyright Polaris Industries Inc.

  • Page 269: Fuel System Troubleshooting

    • High percentage of cylinder leakdown (worn engine) • Injector failure • Low compression (worn engine) • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.41 © Copyright Polaris Industries Inc.

  • Page 270: Digital Wrench Operation

    Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations: •...

  • Page 271: Digital Wrench® Communication Errors

    DIGITAL WRENCH® SERIAL NUMBER LOCATION Open the configuration screen by clicking on the wrench icon. The serial number is located on the right side of the screen. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.43 © Copyright Polaris Industries Inc.

  • Page 272: Digital Wrench® Version And Update

    2. Locate the “Service and Warranty” drop-down menu. 3. Click on “Digital Wrench Updates”. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. 4. The Digital Wrench® portal website should appear in a new web browser.
  • Page 273 Do not "run" or "open" the file from where they are. Select "save" and download them to your PC before running the install. NOTICE Versions and updates are subject to change. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.45 © Copyright Polaris Industries Inc.

  • Page 274: Digital Wrench® Feature Map

    FUEL SYSTEM DIGITAL WRENCH® FEATURE MAP 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.46 © Copyright Polaris Industries Inc.

  • Page 275: Engine Controller Reprogramming (Reflash)

    Request Code in the box provided on the Reflash Authorization site. The Request Code is automatically • Proceed to http://polaris.diagsys.com for specific generated by Digital Wrench® during the reprogramming information and FAQs on how to troubleshoot process.
  • Page 276 All characters are letters; there are no numbers in a request code. NOTICE Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen. 6. Select “Engine Controller Reprogramming”. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.48 © Copyright Polaris Industries Inc.
  • Page 277 PC during the process. 15. Once reprogramming procedure complete, click the ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 4.49 © Copyright Polaris Industries Inc.

  • Page 278: Etc Learn Procedure

    (PMDW) • Device must be set to allow the installation of non- market applications Polaris Mobile Digital Wrench (PMDW) is a diagnostic software application (app) designed specifically for • An electronic user’s guide is provided within the app. Android™ devices. When paired with the Wireless To access the user’s guide, launch the app, and then...
  • Page 279 ................5.32 TROUBLESHOOTING 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 280: General Information - Pvt System

    (initial vehicle movement), clutch upshift and backshift. During the development of Bosch Automotive Service Solutions: the Polaris vehicle, the PVT system is matched first to the 1-800-345-2233 or http://polaris.service-solutions.com engine power curve; then to average riding conditions vehicle’s...

  • Page 281: Service Specifications - Pvt System

    Length Drive Clutch 000-.005” Button to Tower Clearance Drive Clutch 1.374” (34.89 1.372” (34.86 Shaft Diameter Vespel® Thrust 0.030” (0.76 mm) 0.025” (0.64 Washer Thickness 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 282: Pvt System Overview

    In this respect, the PVT subjected to frequent water forging. system is similar to a power governor. Rather than vary throttle position, as a conventional governor does, the 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 283: Overheating / Diagnosis

    PVT system. full position for more than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD Clutch malfunction. certified technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or Poor engine performance.

  • Page 284: Clutch Chart

    (5139684) (7044111) 2018 1000 Models 0-1800 Meters 27-98 Black 3235964 (0-6000 Feet) (5140604) (7044655) 1800-3700 Meters 27-89 Black 3235964 (6000 - 12000 Feet) (5138015) (7044655) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 285: Pvt System Service

    CLAMP, WORM DRIVE SEAL, OUTER BRACKET, SCREEN BELT SEAL, COVER INTAKE, FENDER REAR CLAMP, NARROW DUCT, CLUTCH INTAKE INNER CLUTCH COVER CLAMP, BAND HOSE, CLUTCH AIR INLET 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 286: Pvt Covers And Ducting Components - High Lifter

    SEAL, OUTER INNER CLUTCH COVER COVER, INTAKE BOTTOM SEAL, COVER HOSE, CLUTCH AIR INLET COVER, INTAKE TOP ASM, BOLT / WASHER HOSE, CLUTCH AIR OUTLET 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 287: Pvt Disassembly

    6. Remove the fuel line from the inner clutch cover clutch. restraint. 7. Remove the bolts that retain the inner clutch cover to the engine and transmission. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 288: Pvt Assembly

    Inner Clutch Cover Bolts: 10 lb-ft (14 Nm) 6. Clean the end of the taper on the crankshaft and the tapered bore inside the drive clutch. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.10 © Copyright Polaris Industries Inc.
  • Page 289 PVT SYSTEM 13. Install the PVT inlet duct hose. Torque the hose clamp to specification. TORQUE PVT Duct Hose Clamps: 3 lb-ft (4 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.11 © Copyright Polaris Industries Inc.

  • Page 290: Drive Belt Service

    PVT cover to ease of clutch cover removal. 7. Remove belt off the bottom of the driven clutch and slowly turn the driven clutch counter-clockwise to aid in removal. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.12 © Copyright Polaris Industries Inc.

  • Page 291: Belt Inspection

    On Non-EBS & EBS Models, the driven clutch mounting bolt should be loose to allow the clutch sheaves to spread. TORQUE Driven Clutch Retaining Bolt: 43 lb-ft (58 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.13 © Copyright Polaris Industries Inc.

  • Page 292: Drive Clutch Service

    Cover Bushing 290 ft-lb (393 Nm) (Apply 0.4 mL Loctite® 620™) Shift Weight Cover Bolt Cover Bolt 20 in-lb (2 Nm) 8 ft-lb (11 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.14 © Copyright Polaris Industries Inc.

  • Page 293: Drive Clutch Disassembly

    MUST be replaced. spacer. Belt life will be greatly reduced. 3. Remove cover bolts evenly in a cross pattern and remove cover plate. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.15 © Copyright Polaris Industries Inc.

  • Page 294: Bearing Inspection

    Excessive drag in the bearing may cause difficult Color White / Blue shifting or vehicle creep at idle. Free Length 3.219″ (81.76 mm) Spring Wire Diameter 0.177″ (4.50 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.16 © Copyright Polaris Industries Inc.

  • Page 295: Shift Weight Inspection

    Button to Tower Clearance: 0.000-.012″ (.000-.304 mm) 2. Inspect the tower sheave surfaces that the buttons slide on. Replace the drive clutch if worn, damaged or cracked. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.17 © Copyright Polaris Industries Inc.

  • Page 296: Spider Removal

    Clutch Spider Removal / Installation Tool (PN 2870341). Spider Removal / Installation Tool: 2870341 Clutch Holding Fixture: 2871358-A 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.18 © Copyright Polaris Industries Inc.

  • Page 297: Drive Clutch Inspection

    Measure the thickness and compare to specification. Replace if worn or damaged. MEASUREMENT Thrust Washer Thickness: Standard: .030″ (.76 mm) Service Limit: .025″ (.64 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.19 © Copyright Polaris Industries Inc.

  • Page 298: Moveable Sheave Bushing Inspection

    Bushing Removal /Installation Tool P-90 Driven Clutch 5020631 Cover Bushing Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.20 © Copyright Polaris Industries Inc.
  • Page 299 16. Install nut on puller rod and hand tighten. Turn barrel 3. Remove nut from puller rod and set aside. to apply additional tension if needed. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.21 © Copyright Polaris Industries Inc.
  • Page 300 32. Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed. 33. Turn clutch cover counterclockwise on puller rod until bushing is seated. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.22 © Copyright Polaris Industries Inc.

  • Page 301: Drive Clutch Assembly

    4. Apply 0.4 mL of Loctite® 620™ and 0.4 mL of Loctite® 7088™ Primer in 90° apart in vertical stripes to the shaft threads. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.23 © Copyright Polaris Industries Inc.
  • Page 302 12. Install cover bolts and torque in a cross pattern evenly to specification. TORQUE Drive Clutch Cover Bolts: 8 ft-lb (11 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.24 © Copyright Polaris Industries Inc.

  • Page 303: Driven Clutch Service (Non-Ebs)

    3. Place the driven clutch into the Universal Clutch Compressor PU-50518. Spin the compressor tool handle down to apply downward pressure on the spring cup (C). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.25 © Copyright Polaris Industries Inc.

  • Page 304: Clutch Assembly (Non-Ebs)

    11. Clean and inspect splines on helix and transmission input shaft. 12. Lube splines with a light film of grease. Do not lubricate the bearings! 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.26 © Copyright Polaris Industries Inc.

  • Page 305: Driven Clutch Service (Ebs)

    Remove the spider assembly and spring. Universal Clutch Compressor: PU-50518-A NOTICE Spring is compression only and has no torsional wind. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.27 © Copyright Polaris Industries Inc.

  • Page 306: Clutch Inspection

    9. Pull out the clutch slider pins and sliders 2. Inspect the compression spring for cracks or other damage. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.28 © Copyright Polaris Industries Inc.
  • Page 307 The flanged bearings are not serviceable. If either clutch sheave bearing requires replacement, the entire driven clutch assembly must be replaced. Refer to the Polaris Electronic Parts catalog for specific parts availability. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.29...

  • Page 308: Driven Clutch Assembly

    2. Install the square sliders and slider pins 6. Align the X’s on the spider and moveable sheave. 3. Install the spring pins to retain the slider pins. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.30 © Copyright Polaris Industries Inc.
  • Page 309 9. Once back together, verify the grease / tape marks made during disassembly are properly aligned. 10. Install the drive clutch on the vehicle. See PVT Assemblypage 5.10 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.31 © Copyright Polaris Industries Inc.

  • Page 310: Troubleshooting - Pvt System

    -Worn spider rollers / worn spider spider. roller washers -Replace spider rollers / spider roller washers -Wrong belt for application. -Replace with correct belt. Drive belt turns over 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.32 © Copyright Polaris Industries Inc.
  • Page 311 Grooving on the inner cogs of belt Sticking of the Flange Sleeve Sleeve Bushings, EBS Spring, and next to Stationary Sheave. Assembly Drive Helix. Clean / Replace as necessary 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.33 © Copyright Polaris Industries Inc.
  • Page 312 Verify EBS spring is in the proper position. Clunking noise on drive away Normal operation No action needed 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 5.34 © Copyright Polaris Industries Inc.
  • Page 313 .............6.35 TROUBLESHOOTING - TRANSMISSION 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 314: General Information - Transmission

    2871698 Rear Output Seal Driver (Part of 2871702 Kit) 2871699 Rear Driveshaft Seal (Part of 2871702 Kit) Guide Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 315: Transmission Assembly View

    TRANSMISSION TRANSMISSION ASSEMBLY VIEW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 316 101. Planet Gear Bearing, Ball Dog, Engagement 102. Ring Gear, 53T Bearing, Ball Shift Dog, Park 104. Screw, M8 x 1.25 x 25 Bearing, Ball Gear, 46T 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 317: Transmission Vent Line Routing

    The transmission vent line runs along the rear passenger side frame. It is secured along the front frame by one retention clip as shown. The vent line ends its routing secured into a vertical section of the frame with a vent line termination fitting. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 318: Shift Cable Service

    (H) to the shift lever (D). Disconnect cable end from the lever. 5. Remove the retaining ring (J) and slide the shift lever (D) off the mounting bracket and out from the frame. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 319: Shift Cable Adjustment

    6. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut (E) against the mount. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 320: Transmission Service

    ETC (B), fuel injectors (C), rear differential relay and solenoid (D). Remove the five plastic tie straps (E) retaining the harness to the intake plenum. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 321 16. Using a 15 mm socket, remove the four bolts from the left side (U) and right side (V), securing the transmission to the engine. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 322 Have an assistant help guide the transmission in and out of the vehicle while using a hoist to prevent personal injury or damage to vehicle components. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.10 © Copyright Polaris Industries Inc.

  • Page 323: Transmission Installation

    4 to properly position the clutch DO NOT torque fasteners at this time. center distance. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.11 © Copyright Polaris Industries Inc.
  • Page 324 17 lb-in (2 Nm) 16. Install the fastener securing the bottom of the intake plenum to the rear transmission mount. Torque fastener to specification. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.12 © Copyright Polaris Industries Inc.
  • Page 325 Install the retaining clip (M). jam nut (U), tighten the lower jam nut (V) to secure the shift cable in the bracket. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.13 © Copyright Polaris Industries Inc.

  • Page 326: Transmission Mounting Torque Values

    26. Install both rear drive shafts. Refer to “Rear Drive Shaft Installation”page 7.38 procedure. TRANSMISSION MOUNTING TORQUE 27. Install the front propshaft. Refer to “Front Propshaft VALUES Removal / Installation”page 7.9 procedure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.14 © Copyright Polaris Industries Inc.

  • Page 327: Differential Operation

    This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.15 © Copyright Polaris Industries Inc.
  • Page 328 Female Gear Assembly Differential Cover Assembly Planetary Differential Assembly Fasteners Engagement Dog Bearing Shift Fork Retainer Fastener Torsion Spring Retainer Shift Fork Solenoid Spring Solenoid 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.16 © Copyright Polaris Industries Inc.

  • Page 329: Transmission Disassembly

    6. Remove the compression spring (H). CAUTION Do not pry on case sealing surfaces.Use only the designated pry points on the transmission. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.17 © Copyright Polaris Industries Inc.
  • Page 330 (U) on a clean surface for inspection. If disassembly is required, refer to “Gear Cluster Disassembly”page 6.19. 17. Slide engagement dog (X) off of shift fork guides. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.18 © Copyright Polaris Industries Inc.

  • Page 331: Gear Cluster Disassembly

    4. Tilt the two shafts towards each other and remove the silent chain from the two shafts. 20. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.19 © Copyright Polaris Industries Inc.

  • Page 332: Snorkel Shaft Removal / Disassembly

    CAUTION Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.20 © Copyright Polaris Industries Inc.
  • Page 333 5. Use an arbor press to remove the snorkel tube from the snorkel shaft. 6. Remove the snap ring (A) and shim (B) retaining the bearing in the snorkel tube. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.21 © Copyright Polaris Industries Inc.

  • Page 334: Planetary Differential Disassembly

    If bushing replacement is required, proceed to Planetary Differential Bushing Replacement”. 2. Remove the six screws retaining the differential cover and remove the cover. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.22 © Copyright Polaris Industries Inc.

  • Page 335: Planetary Differential Bushing Replacement

    7. Press the new bushing into the planet gear until it is flush on each end. Repeat this procedure for the remaining planet gears. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.23 © Copyright Polaris Industries Inc.
  • Page 336 14. Press the new bushing into the side gear until it bottoms out. 11. Install the bushing to the specified depth as shown. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.24 © Copyright Polaris Industries Inc.

  • Page 337: Planetary Differential Assembly

    4. Apply Loctite® 2760 to cover screws. corresponding grade. TORQUE Differential Cover Screws (8.8 Fastener): 18–22 lb-ft (24–30 Nm) TORQUE Differential Cover Screws (10.9 Fastener): 28 ft-lbs (38 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.25 © Copyright Polaris Industries Inc.

  • Page 338: Gear / Shaft / Bearing Inspection

    TRANSMISSION GEAR / SHAFT / BEARING INSPECTION 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.26 © Copyright Polaris Industries Inc.

  • Page 339: Snorkel Gear Backlash Procedure

    Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.27 © Copyright Polaris Industries Inc.
  • Page 340 If you have a hard time seeing into the hole, insert a small Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.28 © Copyright Polaris Industries Inc.
  • Page 341 (4th notch). 15. Once the backlash is set, apply Loctite ® 242 to the threads and install the locking screw to secure the snorkel tube. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.29 © Copyright Polaris Industries Inc.

  • Page 342: Transmission Assembly

    Torque specification. TORQUE Shift Fork Screws: 17 lb-ft (23 Nm) 4. Slide engagement dog (U) onto retaining pins of shift fork. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.30 © Copyright Polaris Industries Inc.
  • Page 343 Be sure the shift forks are engaged into the engagement dogs. NOTICE Shift fork pins should be offset towards the input shaft as shown above. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.31 © Copyright Polaris Industries Inc.
  • Page 344 (.070" or 1.8 mm from outer face of bore). 12. Apply a continuous bead of Crankcase 3-Bond Sealant (PN: 2871557) to the left hand transmission mating surface. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.32 © Copyright Polaris Industries Inc.
  • Page 345 Install the shift shaft assembly and sector gear (11T) into the bushing pocket on the left side. Align the timing marks on the gears as shown. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.33 © Copyright Polaris Industries Inc.
  • Page 346 Install the nut and torque to specification. 26. Refer to Transmission Installationpage 6.11 to complete the repair. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.34 © Copyright Polaris Industries Inc.

  • Page 347: Troubleshooting - Transmission

    If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.35 © Copyright Polaris Industries Inc.
  • Page 348 TRANSMISSION NOTES 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 6.36 © Copyright Polaris Industries Inc.
  • Page 349 DRIVE SHAFT SERVICE ................7.39 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 350 ................7.44 DRIVE SHAFT CUTAWAY VIEW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 351: General Information - Final Drive

    TOOL DESCRIPTION PART NUMBER Roll Pin Removal Tool 2872608 Axle Boot Clamp Tool PU-48951 CV Boot Clamp Pliers 8700226 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 352: Front Gearcase Vent Line Routing

    The front gearcase vent line runs along the front passenger side frame. It is secured along the front frame by three retention clips, one horizontal and two vertical as shown. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 353: Front Bearing Carrier Service

    The bearing should rotate quietly and smoothly with no detectable up and down movement and minimal movement sideways between the inner and outer races. Visually inspect for moisture, dirt or corrosion. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 354: Bearing Replacement

    1. Install the end of the drive shaft through the backside of the bearing carrier. 2. Install the upper and lower ball joint ends into the front bearing carrier. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 355 10. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around the end of the shaft. Install the center cap and/or rubber dust cap. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 356: Front Drive Shaft Service

    FRONT DRIVE SHAFT INSTALLATION 1. Install new spring ring on the end of the drive shaft. Apply an anti-seize compound to splines. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 357: Front Propshaft Service

    5. Reverse this procedure to reinstall the front propshaft. Use a NEW roll pin upon installation. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 358 4. Install rear skid plate. 5. Install front skid plate. 6. Install front section of the propshaft. 7. Install the front gearcase (see Front Gearcase Installationpage 7.23). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.10 © Copyright Polaris Industries Inc.

  • Page 359: Propshaft U-Joint Service

    ID than the U-joint cap OD on one end. 5. Tighten clamp with hand tools to force U-joint cups out of yoke. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.11 © Copyright Polaris Industries Inc.

  • Page 360: Propshaft U-Joint Assembly

    8. Tighten clamp until both caps are flush with yoke and one cap is past retaining ring groove 4. Place caps into yoke bores and align with U-joint ends by hand. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.12 © Copyright Polaris Industries Inc.
  • Page 361 12. Install second retaining ring with sharp, square edge facing away from U-joint. 13. Verify the U-joint moves freely and does not bind. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.13 © Copyright Polaris Industries Inc.

  • Page 362: Front Gearcase Service

    Cover Screws, M6 (T30 Torx) Grommet Cover Plate Assembly Fill Plug Gearcase Housing Drain Plug, Magnetic Clutch Housing (Ring Gear) Retaining Ring, External Roll Cage 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.14 © Copyright Polaris Industries Inc.

  • Page 363: All Wheel Drive Operation

    The front drive will remain engaged until the torque requirement goes away (i. e. rear wheels regain traction). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.15 © Copyright Polaris Industries Inc.

  • Page 364: Awd Diagnosis

    8. Inspect the rollers for nicks and scratches. The rollers must slide up, down, in and out freely within the roll cage sliding surfaces and H-springs. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.16 © Copyright Polaris Industries Inc.

  • Page 365: Front Gearcase Removal

    8. Remove the grease zerk fitting from the left front lower control arm. 9. Remove the front gearcase from the left-hand side between the upper and lower control arms. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.17 © Copyright Polaris Industries Inc.
  • Page 366 . Refer to “AWD Diagnosis”page 7.16 for detailed inspection process. 6. Remove the clutch housing / ring gear and roll cage assembly from the gearcase housing. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.18 © Copyright Polaris Industries Inc.
  • Page 367 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.19 © Copyright Polaris Industries Inc.

  • Page 368: Front Gearcase Assembly

    Bearing Roller Surface Spacer Thrust Bearing 16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.20 © Copyright Polaris Industries Inc.
  • Page 369 6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.21 © Copyright Polaris Industries Inc.
  • Page 370 Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. TORQUE Front Gearcase Cover Plate Screws: 7–11 lb-ft (10–15 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.22 © Copyright Polaris Industries Inc.

  • Page 371: Front Gearcase Installation

    6. Drive a new roll pin into the front propshaft yoke. 7. Install the drive shafts into the front gearcase. Refer “Front Gearcase Installation”page 7.23 procedure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.23 © Copyright Polaris Industries Inc.

  • Page 372: Front Gearcase (Adc)

    During engine braking the front drive can also speed differentiate across the axle when turning. Also, if the outer wheel slips or loses traction the inner wheel will then begin to slow the vehicle as well. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.24 © Copyright Polaris Industries Inc.

  • Page 373: Disassembly / Inspection, Front Gearcase (Adc)

    7. Remove the torsion spring retainer Press on the output hub assembly while lifting up on the outer cover plate to prevent removing more than the cover plate. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.25 © Copyright Polaris Industries Inc.
  • Page 374 10. Remove the LH output hub 13. Inspect the ring gear for inconsistent wear patterns or damage. The surfaces should be free of nicks or burrs. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.26 © Copyright Polaris Industries Inc.
  • Page 375 16. Drill a hole in the input shaft seal and remove the seal using a pry bar or seal puller. 19. Inspect the input shaft bushing for wear. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.27 © Copyright Polaris Industries Inc.

  • Page 376: Reassembly, Front Gearcase (Adc)

    6. Install the LH output hub into the gearcase housing. The output hub should spin freely. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.28 © Copyright Polaris Industries Inc.
  • Page 377 The output hub should spin freely. 10. Align the spring retainer dowel pin with the ring gear dowel pin and install the retainer on top of the torsion spring. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.29 © Copyright Polaris Industries Inc.
  • Page 378 16. Fill the gearcase with fluid. FLUID CAPACITY Demand Drive Hub Fluid 8.97 oz. (265 ml) 17. Install the drain plug. Torque to specification. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.30 © Copyright Polaris Industries Inc.

  • Page 379: Troubleshooting, Front Gearcase (Adc)

    If it locks vehicle. to the drive train in only one direction, ADC is not indexing cage in both directions 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.31 © Copyright Polaris Industries Inc.
  • Page 380 If pole faces are severely problem has been fixed. If worn and damaged, not, continue onto replace output cover. additional problems listed. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.32 © Copyright Polaris Industries Inc.
  • Page 381 If only one band of wear is present (or if there is wear between the two bands, inspect the coil area as indicated in Step 4. A band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.33 © Copyright Polaris Industries Inc.
  • Page 382 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.34 © Copyright Polaris Industries Inc.

  • Page 383: Rear Bearing Carrier Service

    (C). the bearing carrier. 8. Remove the bearing carrier. Inspect the bearing again for smoothness and side to side movement, replace as needed. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.35 © Copyright Polaris Industries Inc.

  • Page 384: Rear Bearing Carrier Bearing Replacement

    A-arm. Install the lower bearing carrier fastener. or damage. Replace rear bearing carrier if damaged. 4. Replace the bearing carrier bushings if worn or damaged. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.36 © Copyright Polaris Industries Inc.
  • Page 385 (E). Torque the wheel hub castle nut to specification and install a NEW cotter pin (F). TORQUE Rear Wheel Hub Castle Nuts: 110 lb-ft (149 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.37 © Copyright Polaris Industries Inc.

  • Page 386: Rear Drive Shaft Service

    5. Refer to Rear Bearing Carrier Installationpage 7.36 procedure to reassemble the vehicle. 4. Refer to the “DRIVE SHAFT SERVICE”page 7.39 section if repairing the drive shaft. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.38 © Copyright Polaris Industries Inc.

  • Page 387: Drive Shaft Service

    OUTER CV JOINT / BOOT REPLACEMENT 1. Use a side cutters to cut and discard the boot clamps. NOTICE Tap on inner race only! 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.39 © Copyright Polaris Industries Inc.
  • Page 388 8. Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.40 © Copyright Polaris Industries Inc.

  • Page 389: Inner Plunging Joint / Boot Replacement

    Before you remove your instrument, be sure the small end of the boot is in its correct location on the shaft. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.41 © Copyright Polaris Industries Inc.
  • Page 390 9. Visually inspect joint for damage. Replace if needed. 10. Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.42 © Copyright Polaris Industries Inc.
  • Page 391 19. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.43 © Copyright Polaris Industries Inc.

  • Page 392: Drive Shaft Cutaway View

    FINAL DRIVE DRIVE SHAFT CUTAWAY VIEW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 7.44 © Copyright Polaris Industries Inc.
  • Page 393 ................8.26 REMOVAL / INSTALLATION 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 394 .................8.27 SPRING REPLACEMENT 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 395: General Information - Steering / Suspension

    SPECIAL TOOLS - STEERING / SUSPENSION TOOL DESCRIPTION PART NUMBER Ball Joint Tool PU-50506 Spring Compressor Tool 2870623 Shock Spanner Wrench 2871095 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 396: Steering Assembly Service

    WHEEL, STEERING BOLT SHAFT, STEERING, UPPER / SCREW LOWER ASM, GEAR BOX, STEERING BOLT BUSHING, STEERING CAP, STEERING WHEEL PIN, COTTER ASM, SHOCK, OIL LOCKING 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 397 SHAFT, STEERING, UPPER BOLT ASM, GEAR BOX, STEERING SCREW ASM, TILT STEERING BOLT BUSHING, STEERING ASM, POWER STEERING SCREW PIN, COTTER CAP, STEERING WHEEL BOLT 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 398: Steering Wheel Removal (Non-Eps)

    4. Remove the steering shaft, pivot tube and steering wheel from the vehicle as an assembly. 5. Refer to steps 11-13 of the “Steering Shaft Bearing Replacement”page 8.8 procedure for installation. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 399: Steering Wheel / Upper Steering Shaft Removal (Eps)

    4. Remove the fastener retaining the upper steering shaft to the power steering unit. 5. Remove the steering wheel, upper steering shaft and pivot out as an assembly. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 400: Steering Shaft Bearing Replacement

    13. Wipe the pivot tube clean of any excess Loctite ®. 14. Install steering wheel cap and field test steering operation. REF DESCRIPTION STEERING WHEEL HUB INSERT BUSHING SHAFT, UPPER TILT ASSEMBLY 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 401: Power Steering Unit Removal

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

  • Page 402: Steering Inspection

    Steering Wheel Tilt Assembly Fasteners: Due to the critical nature of the procedures outlined in 40 lb-ft (54 Nm) this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized 10. Reconnect both electrical harnesses onto the power Polaris MSD certified technician.

  • Page 403: Tie Rod End / Wheel Hub Inspection

    (A) is 1/8-1/4 in (3.2-6.4 mm) wider than the measurement at the rear (B). MEASUREMENT Wheel Toe-Out (A) - (B): 1/8-1/4 in (3.2-6.4 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.11 © Copyright Polaris Industries Inc.

  • Page 404: Wheel Toe Adjustment

    To adjust toe alignment: • Hold tie rod end to keep it from rotating. • Loosen jam nuts at both end of the tie rod. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.12 © Copyright Polaris Industries Inc.

  • Page 405: Suspension Service

    Serious injury may result if machine tips or falls. Be sure machine is secure before adjusting. 2. Remove the upper shock mounting bolts from each side of the vehicle. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.13 © Copyright Polaris Industries Inc.

  • Page 406: Front A-Arm Service

    BEARING, BALL SEALED FITTING, ZERK SHIELD, CV JOINT, BALL RIVET RING, RETAINER EXT SCREW SHAFT, PIVOT SCREW SHAFT, PIVOT WASHER BUSHING SCREW CARRIER, BEARING NUT, FLANGE 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.14 © Copyright Polaris Industries Inc.

  • Page 407: Front A-Arm Assembly View - High Lifter

    FRONT A-ARM ASSEMBLY VIEW - HIGH LIFTER DESCRIPTION DESCRIPTION A-ARM, FRONT UPPER A-ARM, FRONT LOWER PIVOT TUBE BEARING CARRIER BUSHING BEARING BOLT RETAINING RING ZERK FITTING BOLT BALL JOINT WASHER 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.15 © Copyright Polaris Industries Inc.

  • Page 408: Front Lower A-Arm Removal

    Wheel Nuts (Aluminum): 120 lb-ft (163 Nm) WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.16 © Copyright Polaris Industries Inc.

  • Page 409: Front Upper A-Arm Removal

    Wheel Nuts (Steel): 60 lb-ft (81 Nm) Wheel Nuts (Aluminum): 120 lb-ft (163 Nm) WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.17 © Copyright Polaris Industries Inc.

  • Page 410: Ball Joint Service

    (PU-50506) on the upper ball joint. To service the lower ball joint: 6. Remove and discard the lower ball joint pinch bolt. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.18 © Copyright Polaris Industries Inc.

  • Page 411: Ball Joint Installation

    Installation Adapter and Spacer. IMPORTANT New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.19 © Copyright Polaris Industries Inc.
  • Page 412 Front Shock Mounting Bolts: 40 lb-ft (54 Nm) Front Caliper Mounting Bolts: 30 lb-ft (41 Nm) Wheel Nuts (Steel): 60 lb-ft (81 Nm) Wheel Nuts (Aluminum): 120 lb-ft (163 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.20 © Copyright Polaris Industries Inc.

  • Page 413: Rear A-Arm Service

    DESCRIPTION DESCRIPTION A-ARM, REAR UPPER BOLT A-ARM, REAR LOWER WASHER BEARING CARRIER BEARING PIVOT TUBE RETAINING RING PIVOT TUBE BOLT BUSHING BOLT ZERK FITTING 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.21 © Copyright Polaris Industries Inc.

  • Page 414: Rear A-Arm Assembly View - High Lifter

    REAR A-ARM ASSEMBLY VIEW - HIGH LIFTER DESCRIPTION DESCRIPTION A-ARM, REAR UPPER WASHER A-ARM, REAR LOWER BEARING CARRIER PIVOT TUBE BEARING BUSHING RETAINING RING BOLT BOLT ZERK FITTING 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.22 © Copyright Polaris Industries Inc.

  • Page 415: Rear Upper A-Arm Removal

    7. Using a 15 mm socket and open-end wrench, remove the two fasteners retaining the upper A-arm to the frame. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.23 © Copyright Polaris Industries Inc.

  • Page 416: Rear Lower A-Arm Removal

    7. Remove the fastener retaining the lower A-arm to the bearing carrier. 8. Remove the lower A-arm from the vehicle. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.24 © Copyright Polaris Industries Inc.

  • Page 417: Rear Stabilizer Bar / Linkage Service

    REAR STABILIZER BAR / LINKAGE SERVICE REAR STABILIZER BAR ASSEMBLY VIEW PART DESCRIPTION PART DESCRIPTION STABILIZER BAR BUSHING LINKAGE BOLT RUBBER BUSHING, BUSHING BRACKET ZERK FITTING 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.25 © Copyright Polaris Industries Inc.

  • Page 418: Removal / Installation

    5. Reverse this procedure for installation. 6. Torque the stabilizer bar mounting bolts and upper rubber linkage bushing nuts to specification. TORQUE Stabilizer Bar Fasteners: 17 lb-ft (23 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.26 © Copyright Polaris Industries Inc.
  • Page 419 3. Reverse the procedure to reinstall the shock. Torque new shock mounting fasteners to specification. TORQUE Shock Mounting Bolts: 40 lb-ft (54 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.27 © Copyright Polaris Industries Inc.
  • Page 420 STEERING / SUSPENSION NOTES 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 8.28 © Copyright Polaris Industries Inc.
  • Page 421 ................9.28 CALIPER ASSEMBLY 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 422 ................... .9.33 BRAKES LOCK 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 423: General Information - Brake System

    MAX LEVEL line! • Adjust the caliper stop pin after pad service. When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). • Check and adjust master cylinder reservoir fluid level after pad service.

  • Page 424: Service Specifications - Brake System

    Rear Brake Disc Runout 0.010" (0.254 mm) Rear Caliper Piston Bore I.D. 1.505" (38.23 mm) 1.507" (38.28 mm) Rear Caliper Piston O.D. 1.500" (38.10 mm) 1.498" (38.05 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 425: Brake System Service

    CALIPER, BRAKE - REAR RH CALIPER, BRAKE - REAR LH LINE, BRAKE - REAR LH FITTING, CROSS CYLINDER, BRAKE MASTER LINE, BRAKE - FRONT LH CALIPER, BRAKE LH SCRAPER 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 426: Brake Line Routing

    BRAKE SYSTEM BRAKE LINE ROUTING FRONT BRAKE LINES FROM CALIPERS TO MASTER CYLINDER 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.
  • Page 427 BRAKE SYSTEM REAR BRAKE LINE FROM MASTER CYLINDER TO JUNCTION BLOCK REAR BRAKE LINES FROM JUNCTION BLOCK TO REAR CALIPERS 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 428: Brake Bleeding / Fluid Change

    Maintain at least 1/2"(1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder. 13. Tighten bleeder screw and remove bleeder hose. Polaris DOT 4 Brake Fluid P/N: Torque bleed screw to specification. 2872189 TORQUE 5.
  • Page 429 Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2" (1.3 cm). 17. Check brake system for fluid leaks. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual © Copyright Polaris Industries Inc.

  • Page 430: Master Cylinder Service

    4. Follow the “Brake Bleeding / Fluid Change” procedure. 5. Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.10 © Copyright Polaris Industries Inc.

  • Page 431: Foot Brake Pedal Service

    2. Remove the retaining clip and clevis pin from the master cylinder to free it from the brake pedal. 3. Slide the brake pedal and bushings off the pedal mount bracket. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.11 © Copyright Polaris Industries Inc.

  • Page 432: Front Brake Pad Service

    6. Remove the inner pad from the bracket and caliper. NOTICE When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.12 © Copyright Polaris Industries Inc.

  • Page 433: Pad Inspection

    4. Slowly pump brake pedal until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in reservoir to prevent air from entering brake system. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.13 © Copyright Polaris Industries Inc.

  • Page 434: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.14 © Copyright Polaris Industries Inc.

  • Page 435: Front Caliper Service

    PART DESCRIPTION Asm, Brake Pad Piston, Brake Asm, Caliper Mount Ring Caliper, Brake Bolt Boot, Pin Seal Bleeder Screw Boot, Pin Bushing Cap, Plug 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.15 © Copyright Polaris Industries Inc.

  • Page 436: Caliper Removal

    5. Loosen brake pad adjustment set screw to allow brake pad removal after the caliper is removed. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.16 © Copyright Polaris Industries Inc.

  • Page 437: Caliper Inspection

    Replace if damaged or worn beyond service limit. MEASUREMENT Front Caliper Piston Bore I.D.: Standard: 1.373" (34.87 mm) Service Limit: 1.375" (34.93 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.17 © Copyright Polaris Industries Inc.

  • Page 438: Caliper Assembly

    NOTICE If brake disc scraper was removed, be sure to reinstall it upon caliper installation. 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. TORQUE Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore Front Caliper Mounting Bolts: smoothly, with light resistance.
  • Page 439 Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. NOTICE If new brake pads are installed, brake burnishing is recommended. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.19 © Copyright Polaris Industries Inc.

  • Page 440: Front Brake Disc Service

    Service Limit: 0.170" (4.32 mm) MEASUREMENT MEASUREMENT Brake Disc Runout: Brake Disc Thickness Variance Service Limit: Service Limit: 0.002” (0.051 mm) 0.010" (0.254 mm) difference between measurements 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.20 © Copyright Polaris Industries Inc.

  • Page 441: Disc Replacement

    Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. TORQUE Front Brake Disc Mounting Bolts: 18 lb-ft (24 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.21 © Copyright Polaris Industries Inc.

  • Page 442: Rear Brake Pad Service

    4. Remove caliper mounting bolts and lift caliper off of disc. NOTICE When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.22 © Copyright Polaris Industries Inc.

  • Page 443: Pad Inspection

    IMPORTANT If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new, clean pads. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.23 © Copyright Polaris Industries Inc.

  • Page 444: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.24 © Copyright Polaris Industries Inc.

  • Page 445: Rear Caliper Service

    PART DESCRIPTION Asm, Brake Pad Piston, Brake Asm, Caliper Mount Ring Caliper, Brake Bolt Boot, Pin Seal Bleeder Screw Boot, Pin Bushing Cap, Plug 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.25 © Copyright Polaris Industries Inc.

  • Page 446: Caliper Removal

    4. Using a hammer and a small punch, remove the piston from the caliper body . Remove the square O-rings from the caliper body 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.26 © Copyright Polaris Industries Inc.

  • Page 447: Caliper Inspection

    Replace if damage is evident or if worn beyond service limit. MEASUREMENT Rear Caliper Piston Bore I.D.: Standard: 1.505" (38.23 mm) Service Limit: 1.507" (38.28 mm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.27 © Copyright Polaris Industries Inc.

  • Page 448: Caliper Assembly

    Be sure groove is clean and free of residue or brakes to specification. may drag upon assembly. TORQUE 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston (D) with a twisting Rear Caliper Mounting Bolts: motion while pushing inward. Piston should slide in 46 lb-ft (62 Nm) and out of bore smoothly with light resistance.
  • Page 449 If the brake drags, re-check assembly and installation. NOTICE If new brake pads are installed, brake burnishing is recommended. Refer to “Brake Burnishing Procedure”page 9.24. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.29 © Copyright Polaris Industries Inc.

  • Page 450: Rear Brake Disc Service

    Service Limit 0.170" (4.32 mm) MEASUREMENT MEASUREMENT Brake Disc Thickness Variance: Service Limit: 0.002” (0.051 mm) Brake Disc RunoutService Limit: 0.010" (0.254 mm) difference between measurements 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.30 © Copyright Polaris Industries Inc.

  • Page 451: Disc Replacement

    Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. TORQUE Rear Brake Disc Mounting Bolts: 28 lb-ft (38 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.31 © Copyright Polaris Industries Inc.

  • Page 452: Troubleshooting - Brake System

    • Worn or damaged master cylinder or components • Damaged break pad noise insulator PEDAL VIBRATION • Disc damaged • Disc worn (runout or thickness variance exceeds service limit) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.32 © Copyright Polaris Industries Inc.

  • Page 453: Caliper Overheats (Brakes Drag)

    • Residue build up under caliper seals • Operator riding brakes BRAKES LOCK • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.33 © Copyright Polaris Industries Inc.
  • Page 454 BRAKE SYSTEM NOTES 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 9.34 © Copyright Polaris Industries Inc.
  • Page 455 ................10.33 MAIN FLOOR REMOVAL 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.1 © Copyright Polaris Industries Inc.
  • Page 456 ............10.37 WINCH REMOVAL / INSTALLATION (PKG ONLY) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.2 © Copyright Polaris Industries Inc.

  • Page 457: General Information - Body / Frame

    2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.3 © Copyright Polaris Industries Inc.

  • Page 458: Chassis Assembly Views

    SUPPORT, FLOOR LH ROCKER, LH WASHER SUPPORT, FLOOR RH ROCKER, RH CLIP, U SPEED NUT PLATE, WINDSHIELD MT SCREW GROMMET BRACKET, WINDSHIELD BOLT SCREW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.4 © Copyright Polaris Industries Inc.
  • Page 459 BODY / FRAME RANGER CREW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.5 © Copyright Polaris Industries Inc.

  • Page 460: Body Components Assembly Views

    CLIP, U SPEED NUT SCREW DASH, PANEL LOWER SCREW RIVET COVER, GLOVEBOX SCREW SCREW GROMMET, RUBBER DASH, PANEL UPPER MOUNT BRACKET, MOUNT HOLDER, CUP 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.6 © Copyright Polaris Industries Inc.

  • Page 461: Hood / Front Fenders / Front Fascia

    BODY / FRAME HOOD / FRONT FENDERS / FRONT FASCIA 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.7 © Copyright Polaris Industries Inc.

  • Page 462: Hood / Front Body Components

    LINER, HOOD FASCIA, FRONT COVER. HOOD GRILLE BRACKET, FRONT FENDER, FRONT RH SCREEN, BUMPER BUMPER FENDER FLAIR, FRONT LATCH, 1/4 TURN FENDER, FRONT LH WASHER 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.8 © Copyright Polaris Industries Inc.

  • Page 463: Floor / Rear Fenders / Skid Plate / Storage

    BODY / FRAME FLOOR / REAR FENDERS / SKID PLATE / STORAGE 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.9 © Copyright Polaris Industries Inc.
  • Page 464 BODY / FRAME RANGER CREW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.10 © Copyright Polaris Industries Inc.

  • Page 465: Seat Mounting / Seat Belts

    ASM, SEAT BACK ASM, SEAT BELT CAP, BOLT HEAD ASM, SEAT BACK BUCKLE, SEAT BELT BRACKET, SEAT HINGE CLAMP, WIRE/TUBE GROMMET WASHER PIN, SEAT LATCH SCREW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.11 © Copyright Polaris Industries Inc.
  • Page 466 BODY / FRAME RANGER CREW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.12 © Copyright Polaris Industries Inc.
  • Page 467 PSNGR BUCKLE, SEAT BELT BRACKET, SEAT HINGE DBL CAP, BOLT HEAD DRIVER BUCKLE, SEAT BELT ASM, SEAT BACK PSNGR WASHER SWITCH BRACKET, SEAT HINGE 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.13 © Copyright Polaris Industries Inc.

  • Page 468: Cab Frame Service

    FRAME, CAB FRONT RH SCREW RIVET NUT, FLANGE HIP BOLSTER BOLT HIP BOLSTER, RH SCREW WASHER HIP BOLSTER, LH NUT, NYLOK BOLT PLATE, WINDSHIELD MOUNT SCREW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.14 © Copyright Polaris Industries Inc.
  • Page 469 HANDLE, GRAB SCREW FRAME, CAB FRONT BOLT FRAME, CAB SIDE LH FRAME, CAB MIDDLE RIVET FRAME, CAB SIDE RH HEADREST BOLT PLATE, WINDSHIELD SCREW MOUNT 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.15 © Copyright Polaris Industries Inc.

  • Page 470: Heater Assembly View (Pkg Only)

    DASH PANEL, LOWER 2& CLAMP, HOSE WORM GEAR DASH PANEL, UPPER STRAP, PANDUIT SCREW SEAL, DEFROST DASH PANEL, CONTROLS SEAL, DASH, CENTER CONTROL, HVAC 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.16 © Copyright Polaris Industries Inc.

  • Page 471: Roof Assembly View (Pkg Only)

    BODY / FRAME ROOF ASSEMBLY VIEW (PKG ONLY) PART DESCRIPTION PART DESCRIPTION KIT, SEAL, ROOF WASHER CLIP, DART ROOF CLIP, NUT HEADLINER SCREW SCREW SCREW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.17 © Copyright Polaris Industries Inc.

  • Page 472: Rear Panel Assembly View (Pkg Only)

    BODY / FRAME REAR PANEL ASSEMBLY VIEW (PKG ONLY) PART DESCRIPTION PART DESCRIPTION PANEL, GLASS SEAL, GLASS SLEEVE SCREW HANDLE WASHER SHIM WASHER BASE WASHER MOUNT 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.18 © Copyright Polaris Industries Inc.

  • Page 473: Door Removal / Installation (Le / Pkg Only)

    Half Door Hinge Fasteners: 14 lb-ft (19 Nm) 4. For installation, reverse removal procedure. Install fasteners and torque to specification. TORQUE Full Door Hinge Fasteners: 17 lb-ft (23 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.19 © Copyright Polaris Industries Inc.

  • Page 474: Heater Removal / Installation (Pkg Only)

    7. Reverse removal process for installation. Torque heater system mounting fasteners to specification. TORQUE Heater Mounting Fasteners: 6–8 lb-ft (8–10 Nm) 5. Disconnect the coolant hoses from the heater system. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.20 © Copyright Polaris Industries Inc.

  • Page 475: Roof Removal / Installation (Pkg Only)

    Store windshield in an upright position in a location where it will not be bumped into and where it will not be subject to things falling on it. Polaris recommends that the lower frame of the glass be set onto a wood or other...

  • Page 476: Windshield Removal / Installation (Pkg Only)

    3. Lift the windshield off the vehicle and store in an upright position. 4. For installation, reverse removal procedure. Torque windshield mount fasteners to specification. TORQUE Windshield Mount Fasteners: 15 lb-ft (20 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.22 © Copyright Polaris Industries Inc.
  • Page 477 6. For installation, reverse the removal procedure and torque the fasteners to specification. TORQUE Wiper Motor Shaft Fastener: 15 lb-ft (20 Nm) Wiper Arm Fastener: 10 lb-ft (14 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.23 © Copyright Polaris Industries Inc.

  • Page 478: Cab Accessories Removal / Installation (Pkg Only)

    3. Disconnect the electrical harness connector from the heater element. Pull the adhesive backing off of the seat to remove the heater element. 4. For installation, reverse removal procedure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.24 © Copyright Polaris Industries Inc.

  • Page 479: Rear Cargo Box Service

    BODY / FRAME REAR CARGO BOX SERVICE TAILGATE / CARGO BOX PANELS ASSEMBLY VIEW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.25 © Copyright Polaris Industries Inc.

  • Page 480: Cargo Box Support Assembly View

    SCREW BUSHING, BOX LATCH SCREW SPRING, LATCH NUT, FLANGE SPRING, LATCH CLIP, HITCHPIN PIN, CLEVIS SCREW RIVET WASHER HANDLE, BOX LATCH SHOCK, BOX DUMP 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.26 © Copyright Polaris Industries Inc.

  • Page 481: Cargo Box Removal

    6. Lift the cargo box from the frame. Two people or an appropriate overhead hoist may be needed to remove the box from the frame. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.27 © Copyright Polaris Industries Inc.

  • Page 482: Body Component Removal

    2. Disconnect both front headlights at the bulbs. Refer to “Headlight Bulb Replacement”page 11.21 procedure. 3. Remove the two fasteners (C) retaining the front fascia to the upper radiator brackets. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.28 © Copyright Polaris Industries Inc.

  • Page 483: Front Fenders Removal

    (J) retaining the front portion of the fender to the frame. 6. Carefully pull the front fascia straight out to remove it from the vehicle. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.29 © Copyright Polaris Industries Inc.

  • Page 484: Dash Panels / Glove Box Removal

    T-40 Torx-head screw inside the glove box in the back. 11. Carefully remove the dash storage panel. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.30 © Copyright Polaris Industries Inc.

  • Page 485: Rocker Panel Removal

    If removing the Left-Hand panel, loosen the hose clamp (R) retaining the fuel fill hose to the Left-Hand panel. 4. Pull rocker panel out to remove it. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.31 © Copyright Polaris Industries Inc.

  • Page 486: Rocker Panel Removal - Crew

    7. Cover the fuel fill hose to prevent leakage and to prevent debris from entering the fuel tank. WARNING Gasoline is extremely flammable and explosive under certain conditions. 8. Installation is reverse of removal. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.32 © Copyright Polaris Industries Inc.

  • Page 487: Main Floor Removal

    4. Lift and remove the main floor from the vehicle. 8. Remove the lower steering shaft. Refer to “Lower Steering Shaft Removal”page 8.7 procedure. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.33 © Copyright Polaris Industries Inc.

  • Page 488: Rear Floor - Crew

    8. Remove the wire harness grommet (D) Fig. 1 to separate the fuse box, ECU and diagnostic connector wire harness from the storage box. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.34 © Copyright Polaris Industries Inc.

  • Page 489: Brushguard Removal / Installation (Pkg Only)

    Front Brushguard Fasteners: 30 lb-ft (41 Nm) 11. Lift the floor panel out of the vehicle. 12. Installation is the reverse order of removal. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.35 © Copyright Polaris Industries Inc.

  • Page 490: Nerf Bar Removal / Installation (Pkg Only)

    Rear Brushguard Fasteners: 12 lb-ft (16 Nm) 3. For installation, reverse removal procedure. Torque fasteners to specification. TORQUE Nerf Bar Fasteners:12–15 lb-ft (16–20 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.36 © Copyright Polaris Industries Inc.

  • Page 491: Winch Removal / Installation (Pkg Only)

    4. Remove the blue and yellow cables to the winch motor. 5. Remove the fasteners holding the winch to the frame and remove the winch. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.37 © Copyright Polaris Industries Inc.
  • Page 492 BODY / FRAME NOTES 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 10.38 © Copyright Polaris Industries Inc.
  • Page 493 ..........11.25 FAN CONTROL CIRCUIT OPERATION / TESTING 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.1 © Copyright Polaris Industries Inc.
  • Page 494 ................. . . 11.46 TROUBLESHOOTING 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.2 © Copyright Polaris Industries Inc.
  • Page 495 ..........11.54 EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.3 © Copyright Polaris Industries Inc.

  • Page 496: General Information - Electrical System

    • Digital Wrench ® Diagnostic Connector* • ECU* • Speed Key Accessory (if installed) NOTICE *Components are located under rear passenger seat base on RANGER CREW models. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.4 © Copyright Polaris Industries Inc.

  • Page 497: Special Tools - Electrical

    47 VAC ± 25% RPM) Stator Leg Voltage (5000 79 VAC ± 25% RPM) Starter Solenoid Terminal 2.5 Ω ± 20% Resistance (77 °F) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.5 © Copyright Polaris Industries Inc.

  • Page 498: Switches / Controls Service

    NOTICE Pins 7 and 8 provide power and ground to light the switch lamp. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.6 © Copyright Polaris Industries Inc.

  • Page 499: Ignition Key Switch

    • Move the switch to TURF. There should be continuity between switch pins 1 and 2; 4 and 5. NOTICE Pins 7 and 8 provide power and ground to light the switch lamp. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.7 © Copyright Polaris Industries Inc.

  • Page 500: Transmission (Gear Position) Switch

    3. Test for continuity between the switch and the ECU pin. 4. Test for continuity across the switch. Seat Belt Switch: Normally Open 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.8 © Copyright Polaris Industries Inc.

  • Page 501: Drive Mode Switch

    3. If the resistance is out of specification for any mode, replace the switch. Drive Mode Switch Performance: 2300 Ω Standard: 3700 Ω Work: 5800 Ω 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.9 © Copyright Polaris Industries Inc.

  • Page 502: Vehicle Speed Sensor Service

    3. Pass a screwdriver back and forth in front of the sensor tip. 4. Be sure connections are good and 9V battery is in good condition. If the light flashes, the sensor is good. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.10 © Copyright Polaris Industries Inc.

  • Page 503: Rear Diff Solenoid Service

    CAUTION Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.11 © Copyright Polaris Industries Inc.

  • Page 504: Differential Solenoid Replacement

    3. To install, reverse the removal procedure. Torque the solenoid fastener to specification. TORQUE Differential Solenoid Nut: 25 lb-ft (34 Nm) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.12 © Copyright Polaris Industries Inc.

  • Page 505: Instrument Cluster Service

    Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.13 © Copyright Polaris Industries Inc.

  • Page 506: Rider Information Display

    11. TURF Indicator - Illuminated when the AWD / TURF switch is in the TURF position. 12. Neutral Gear Indicator - LED icon illuminates when gear selector is in the neutral (N) position. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.14 © Copyright Polaris Industries Inc.

  • Page 507: Information Display Area

    2. To reset to 0, push and hold the MODE button until the distance display changes to 0. Engine hours are logged anytime the engine is running. Total hours can not be reset. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.15 © Copyright Polaris Industries Inc.
  • Page 508 7. Toggle the MODE button until the odometer is and advance to the next display option. displayed. 8. Press and hold the MODE button until the hour segment flashes. Release the button. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.16 © Copyright Polaris Industries Inc.

  • Page 509: Diagnostic Mode

    (SPN). • The third number (located bottom right) can be 1 to 2 digits in length. This number equates to the fault mode (FMI). 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.17 © Copyright Polaris Industries Inc.

  • Page 510: Instrument Cluster Pinouts

    Ground mount. High Beam Input Fuel Level Sensor NOTICE The instrument cluster bezel is a snap-on assembly and is a serviceable part. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.18 © Copyright Polaris Industries Inc.

  • Page 511: Instrument Cluster Installation

    5. Install the upper dash panel and push rivets. AUDIO SYSTEM (LE ONLY) For Instructions on how to use the audio system on this vehicle, consult the booklet included with the vehicle. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.19 © Copyright Polaris Industries Inc.

  • Page 512: All Wheel Drive Coil Service

    80% of all electrical issues are caused by bad/failed connections and grounds. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.20 © Copyright Polaris Industries Inc.

  • Page 513: Headlight Service

    5. Install the new bulb into the housing and rotate it clockwise 90° to lock it in place. NOTICE Make sure the tab on the bulb locates properly in the housing. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.21 © Copyright Polaris Industries Inc.

  • Page 514: Headlight Housing Removal

    7. Carefully push on the face of the headlight housing to disengage the housing tabs from the front fascia brackets. 8. Remove the headlight housing from the vehicle. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.22 © Copyright Polaris Industries Inc.

  • Page 515: Tail Light / Brake Light Service

    4. Install the new LED lamp assembly by reversing this procedure. 5. Test the tail light / brake light after installation to verify proper function. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.23 © Copyright Polaris Industries Inc.

  • Page 516: Cooling System Service

    ELECTRICAL COOLING SYSTEM SERVICE COOLING SYSTEM BREAK-OUT DIAGRAM 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.24 © Copyright Polaris Industries Inc.

  • Page 517: Fan Control Circuit Operation / Testing

    4. If the fan runs with the sensor harness disconnected, but will not turn on when the engine is hot, check the coolant temperature sensor and connector terminals. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.25 © Copyright Polaris Industries Inc.

  • Page 518: Ignition Coil Service

    Ignition Coil Retaining Bolt: 8 lb-ft (11 Nm) 6. Connect the harness connection to the ignition coil and then connect the (-) negative battery cable. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.26 © Copyright Polaris Industries Inc.

  • Page 519: Ignition Coil Tests

    Between High Tension 2.30k Ω ± 5% (PTO) Lead Caps Secondary Between High Tension 2.73k Ω ± 5% (MAG) Lead Caps Primary Test Secondary Test 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.27 © Copyright Polaris Industries Inc.

  • Page 520: Fuse Box: Fuses / Relays / Circuit Break Service

    EPS models have a separate electrical system which includes a 30-amp fuse and relay. Refer to “EPS System Breakout”page 11.51 for EPS electrical component details. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.28 © Copyright Polaris Industries Inc.

  • Page 521: Fuse Box Detail View

    ELECTRICAL FUSE BOX DETAIL VIEW 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.29 © Copyright Polaris Industries Inc.

  • Page 522: Relay Operation

    Provides 12 Vdc power for EFI switch to enable relay. Red / Dark Blue system circuits. Provides 12 Vdc power for EPS Orange operation. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.30 © Copyright Polaris Industries Inc.
  • Page 523 Solenoid. NOTICE The Rear Diff Solenoid Relay is mounted separately, attached to the rear portion of the main frame under the rear cargo box. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.31 © Copyright Polaris Industries Inc.

  • Page 524: Charging System Service

    Charging system damage will occur if incompatible (lights, etc.) and begins to charge the battery. Depending components are installed. Always reference Polaris on battery condition and system load, the break even Electric Parts Catalog for proper part numbers.

  • Page 525: Charging System Stator (Alternator) Tests

    The stator cover can be removed with the engine installed in the chassis. Be sure to thoroughly clean the area around the stator cover prior to removal. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.33 © Copyright Polaris Industries Inc.

  • Page 526: Alternator Replacement (Hvac)

    5. If replacing the regulator / rectifier, remove the two retaining screws and disconnect the wire harness. Remove the regulator and heat sink plate from the vehicle. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.34 © Copyright Polaris Industries Inc.

  • Page 527: Charging System Testing Flow Chart

    Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched: 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.35 © Copyright Polaris Industries Inc.

  • Page 528: Electrical Diagnostics

    • All associated circuits have no shorts to ground. Testing For A Short To Groundpage 11.39 Polaris advises to only use a high quality DMM that meets the same standards as the Fluke™ 77 (PV-43568) • All associated circuits have no shorts to voltage.

  • Page 529: Connector Probing Guidelines

    To avoid causing damage, use of the appropriate adapters is required. Most terminals used on Polaris NOTICE machines can be tested using terminal test kit PV–...

  • Page 530: Testing Continuity/Resistance

    Testing For A Short To Voltagepage 11.40 For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.38 © Copyright Polaris Industries Inc.

  • Page 531: Testing For A Short To Ground

    9. If the DMM reads OL, there is no short to ground. Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltagepage 11.40 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.39 © Copyright Polaris Industries Inc.

  • Page 532: Testing For A Short To Voltage

    Failure to do so can lead to Serious injury and/or damage to the machine. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.40 © Copyright Polaris Industries Inc.

  • Page 533: Testing Current Flow (Amperage)

    9. If over 10 milliamps, go to the fuse block and start systematically removing one fuse at a time until the value drops, indicating the circuit that requires attention. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.41 © Copyright Polaris Industries Inc.

  • Page 534: Testing Voltage Drop

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.42 © Copyright Polaris Industries Inc.

  • Page 535: Battery Service

    Refer to “OCV - Open Circuit Voltage Test”page 11.44 procedure. 5. Charge the battery as recommended. Refer to “Battery Charging Procedure”page 11.45. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.43 © Copyright Polaris Industries Inc.

  • Page 536: Battery Terminal Block

    To prevent shock or component damage, remove spark NOTICE plug high tension leads and connect securely to engine Battery charge can be maintained by using a Polaris ground before proceeding. battery tender charger or by charging once a month to make up for normal self-discharge.

  • Page 537: Battery Conductance Analyzer

    Do not exceed 10 amps when charging the battery. load testing. NOTICE Authorized Polaris dealers/distributors are required to use the conductance analyzer when testing 12V Polaris Charge the battery using an automatic charger that will batteries. not exceed 14.6 Vdc. An automatic charger will signal when charging is complete.

  • Page 538: Starter System Service

    Refer to the voltage drop tests in the “Starting System Testing Flow Chart”page 11.49. Voltage should not exceed .1 DC volts per connection 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.46 © Copyright Polaris Industries Inc.

  • Page 539: Starter Motor Installation

    (bendix) with the flywheel. This helps prevent binding and starter damage. TORQUE Starter Motor Fasteners: 7 lb-ft (10 Nm) 6. Torque upper starter mounting bolt to specification. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.47 © Copyright Polaris Industries Inc.

  • Page 540: Starter Solenoid Operation

    • The key switch must be turned to the “start” position to provide 12V power to the starter solenoid via the Green / White wire. • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.48 © Copyright Polaris Industries Inc.

  • Page 541: Starting System Testing Flow Chart

    ELECTRICAL STARTING SYSTEM TESTING FLOW CHART 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.49 © Copyright Polaris Industries Inc.

  • Page 542: Electronic Power Steering (Eps)

    NOTICE to a normal mechanically coupled steering system. The Verify the EPS unit has the latest software version and system is Polaris Digital Wrench® compatible for calibration loaded before replacing the EPS unit. If not, simplified diagnostics...

  • Page 543: Eps System Breakout

    ELECTRICAL EPS SYSTEM BREAKOUT 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.51 © Copyright Polaris Industries Inc.

  • Page 544: Eps Troubleshooting (Power Steering Non-Functional With Mil On)

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.52 © Copyright Polaris Industries Inc.

  • Page 545: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.53 © Copyright Polaris Industries Inc.

  • Page 546: Eps Troubleshooting (Using Digital Wrench®)

    ELECTRICAL EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual 11.54 © Copyright Polaris Industries Inc.
  • Page 547 Assembly View ............9.15 Service Notes ............9.3 Disassembly ............9.16 Service Specifications ..........9.4 Inspection.............9.17 Special Tools ............9.3 Installation ............9.18 Brake System Inspection ..........2.38 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 548 Radiator Removal ..........3.108 Software Version ............4.42 Specifications ............3.107 Special Tools ............4.42 Thermostat Replacement ........3.109 Updates ...............4.44 Troubleshooting ........... 3.116 Version and Update ID ..........4.44 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual IX.2 © Copyright Polaris Industries Inc.
  • Page 549 Crankshaft Bearing Journal Inspection ......3.52 Crankshaft Installation (1000) ........3.71 Torque Offset Procedure ........11.50 Crankshaft Main Bearing Selection ......3.65 ETC Learn Procedure ........4.24, 4.50 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 550 Front Body Component Detail View............11.29 Front Bumper Removal.......... 10.28 Overview / Operation ..........11.28 Front Fascia Removal ........... 10.28 Relay Operation ........... 11.30 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual IX.4 © Copyright Polaris Industries Inc.
  • Page 551 Reclamation with Recovery / Charging...... 3.126 Test ..............3.29 Oxygen Sensor ............4.34 Replacement............4.34 Ignition Coil Coil Tests ............11.27 Operation Overview ..........11.26 Parasitic ..............11.41 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual IX.5 © Copyright Polaris Industries Inc.
  • Page 552 Ring Installed Gap ..........3.61 Cutaway View............7.44 Piston to Cylinder Clearance (1000) ......3.62 Drive Shaft / CV Joint Handling .........7.39 Polaris Mobile Digital Wrench (PMDW) ......4.50 Inner Plunging Joint / Boot Replacement .....7.41 Power Steering Unit (EPS) Installation ............7.38 Installation ............. 8.9 Outer CV Joint / Boot Replacement ......7.39...
  • Page 553 Static ..............11.36 Stator T-MAP Sensor Cover Installation ...........3.80 Operation Overview ..........4.27 Sensor Replacement ..........4.27 Cover Removal / Inspection ........3.45 Replacement............11.33 Sensor Test............4.27 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual IX.7 © Copyright Polaris Industries Inc.
  • Page 554 EPS Using Digital Wrench®........11.54 Front Gearcase (ADC)..........7.31 HVAC ..............3.143 Misfire Detection ............4.40 PVT System ............5.32 Starting System ........... 11.46 Transmission............6.35 Valve Clearance Adjustment ..........3.93 Inspection.............3.38 9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual IX.8 © Copyright Polaris Industries Inc.
  • Page 555 2018-19 RANGER 900 XP EPS (CHASSIS)
  • Page 556 2018 RANGER 1000 XP CREW EPS (CHASSIS)
  • Page 557 2018-19 RANGER 900 XP EU...
  • Page 558 2018 RANGER 1000 XP EPS HVAC (CHASSIS)
  • Page 559 2018 RANGER 1000 XP MUDDER...
  • Page 560 2018 RANGER 1000 XP EPS (CHASSIS)
  • Page 561 2018-19 RANGER 900 XP CREW EPS (CHASSIS)

This manual is also suitable for:

Ranger xp 1000 2018-2019Ranger crew 900 2018-2019Ranger crew 1000 2018-2019

Table of Contents