Polaris RANGER XP 1000 2018 Service Manual

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2018 RANGER XP 1000

Service Manual

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent

version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer

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 November 2017 (PN 9928487 R01)

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.

Table of Contents

Troubleshooting

Summary of Contents for Polaris RANGER XP 1000 2018

Page 1 Publication Printed November 2017 (PN 9928487 R01) © Copyright 2017 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
Page 2 SAFETY WARNINGS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
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 RANGER XP 1000 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING / EXHAUST CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM CHAPTER 10:...
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 Part Numbers
GENERAL INFORMATION PUBLICATION PART NUMBERS Some vehicle publications, such as the Owner’s Manual and Parts Manual are available on-line and can be downloaded from the Polaris website (www.polarisindustries.com). MODEL MODEL NUMBER OWNER’S MANUAL 2018 RANGER XP 1000 R18RRE99AS / BS, R18RRU99AS / BS...
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
PU-50105 PV-43531 PU-52492 Engine Stand (2” Bore) Engine Stand Adapter (Mounts To Engine Stand Sleeve Adapter (Use The Engine) With 2” Bore Stand) PU-50624 PU-50562 PU-50625 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 10 Flywheel Puller Piston Ring Compressor Pliers Valve Spring Compressor PA-49316 PV-43570-1 PV-1253 or PV-4019 Cylinder Holding & Camshaft Timing Crank Seal Installation Tool Plate PU-52493 PU-50563 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 11 Drive Clutch Holding Fixture Drive Clutch Puller Clutch Compressor Tool PU-52430 PU-52422 PU-50518–A Clutch Bushing Replacement Kit Piston Pin Puller Driven Clutch Separator Tool 2870386 2871226–A 2875911 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 12 Crankcase Sealant 2871282 2871557 (3 bond) 3233901 (Loctite® 680) FINAL DRIVE Roll Pin Removal Tool Axle Boot Clamp Tool CV Boot Clamp Pliers 2872608 PU-48951 8700226 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 13 Digital Wrench® Vehicle Interface Digital Wrench® PC Interface Cable Cable PU-47063-B PU-47470 PU-47469 Digital Wrench® SmartLink Module Digital Wrench® SmartLink Kit Wireless Vehicle Link (WVL) PU-47468 PU-47471 PU-51435 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 14 Static Timing Light Harness Hall Effect Sensor Probe Harness Multimeter 2871745 2460761 PF-51237 Battery Conductance Analyzer Connector Test Kit Timing Light (MDX-610P) PV-43526 2870630 PU-50296 Relay Bypass PU-49466 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.10 © Copyright Polaris Industries Inc.
Page 15: Master Torque List
7 ft-lbs (10 Nm) Outer Clutch Cover 35 in-lbs (4 Nm) Fastener Fastener Oil Pump Pick-Up Oxygen Sensor 18 ft-lbs (24 Nm) 7 ft-lbs (10 Nm) Retaining Fastener 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.11 © Copyright Polaris Industries Inc.
Page 16 35 in-lbs (4 Nm) Coolant Hose Mounting 3.5 lb-ft (4.7 Nm) Bracket Fastener Thermostat Cover 7 ft-lbs (10 Nm) Fastener 6 ft-lbs (8 Nm) Coolant Bleed Fastener 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.12 © Copyright Polaris Industries Inc.
Page 17 Clamps PVT Inlet Hose Clamp 35 in-lbs (4 Nm) PVT Cover to 50 ft-lbs (68 Nm) Transmission Fastener Shift Weight Fastener 20 in-lb (2 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.13 © Copyright Polaris Industries Inc.
Page 18 Lower A-Arm Fastener 45 ft-lbs (61 Nm) Ball Joint Nut 31 ft-lbs (42 Nm) Stabilizer Bar Mount Fastener 17 ft-lbs (23 Nm) Stabilizer Bar Link Fastener 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.14 © Copyright Polaris Industries Inc.
Page 19 28 ft-lbs (38 Nm) Fastener Rear Caliper Mounting 46 ft-lbs (62 Nm) Fastener 8 ft-lbs (11 Nm) Pedal Bracket Nuts Brake Disc Mounting 18 ft-lbs (24 Nm) Fastener 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.15 © Copyright Polaris Industries Inc.
Page 20 AC Hose Clamp Fastener 6 ft lbs (8 Nm) Fastener AC Hose, Condenser to 12 ft-lbs (16 Nm) Handle, Grab Fastener 10 ft-lbs (14 Nm) Evaporator 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.16 © Copyright Polaris Industries Inc.
Page 21 Terminal Block Fasteners 8 lb-ft (11 Nm) Ignition Coil Retaining Bolt Tail Light Fasteners 4 lb-ft (5 Nm) 7 lb-ft (10 Nm) Starter Motor Fasteners 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.17 © Copyright Polaris Industries Inc.
Page 22: Vehicle Identification
1205551 - 18: 999cc Twin Cylinder, Liquid Cooled, 4-Stroke DOHC, Electric Start VEHICLE AND ENGINE SERIAL NUMBER LOCATION Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The engine serial number can be found on a decal applied to the front of the engine crankcase...
Page 23: Vehicle Specifications
1750 lb / 795 kg (Northstar (Payload) Edition) (Includes riders, cargo and accessories) Hitch Towing Capacity 2500 lb / 1134 kg Hitch Tongue Capacity 150 lb / 68 kg 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.19 © Copyright Polaris Industries Inc.
Page 24: Ranger Xp 1000 Specifications
15A Drive 20A Lights 1800-3700 32–97 Black 7044761 30A EPS Meters (1323520) (7044938) 30A HVAC (if applicable) (6000 - 12000 15A Alternator (if applicable) Feet) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.20 © Copyright Polaris Industries Inc.
Page 25: Misc. Specifications And Charts
π (3.14) x Radius² x Height = °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.21 © Copyright Polaris Industries Inc.
Page 26: Standard Bolt Torque Specification
103 (140) 151 (205) 177 (240) 59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.22 © Copyright Polaris Industries Inc.
Page 27: Sae Tap / Drill Sizes
2–12 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.23 © Copyright Polaris Industries Inc.
Page 28: Decimal Equivalents
17/32 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″ 9928487 R01 - 2018 RANGER XP 1000 Service Manual 1.24 © Copyright Polaris Industries Inc.
Page 29 MAINTENANCE LUBRICANTS POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS......2.31 GENERAL VEHICLE INSPECTION AND MAINTENANCE..........2.32 .
Page 31 SPECIAL TOOLS - MAINTENANCE Inspect, clean, lubricate, adjust and replace parts as TOOL DESCRIPTION PART NUMBER necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available Oil Filter Wrench PU-50105 from your Polaris dealer. Shock Spanner Wrench...
Page 32 Transmission Fluid AGL Gearcase Lubricant Brake Fluid DOT 4 Grease Fittings Premium All-Season Grease U-Joint Lubricant Premium U-Joint Lubricant 87 Octane (minimum) 11.5 Gal (43.5 L) Fuel 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 33: Periodic Maintenance
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for • Drive vehicle slowly at first while varying the throttle replacement parts, use genuine Pure Polaris parts position. Do not operate at sustained idle. available from your Polaris dealer.
Page 34 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 35 Initial fluid level inspection; add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual...
Page 36 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual...
Page 37 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual...
Page 38 Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.10...
Page 39 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.11...
Page 40 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.12...
Page 41 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.13...
Page 42 Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.14...
Page 43 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.15...
Page 44 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.16...
Page 45 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.17...
Page 46 Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.18...
Page 47 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.19...
Page 48 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.20...
Page 49 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.21...
Page 50 Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.22...
Page 51 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.23...
Page 52 Inspect for leaks and loose fittings XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.24...
Page 53 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.25...
Page 54 Cam Chain Tensioner XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer perform these services. E - Emission Control System Service (California) When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over.
Page 55 Duty Full Synthetic - On Front Side of Engine 50 hrs thereafter Check level daily; change Engine Coolant Polaris 50 / 50 Extended Life Maintain coolant level in coolant every two years coolant reservoir bottle - Under Front Hood Antifreeze * More often under severe use, such as operation in water or under severe loads.
Page 56 Add lubricant until it is visible at first Transmission Gearcase the fill hole threads Lubricant * More often under severe use, such as operation in water or under severe loads. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.28 © Copyright Polaris Industries Inc.
Page 57 (800 km); Grease before long periods of Propshaft Yoke Premium U-Joint Lubricant Grease middle fitting storage, and after thoroughly washing or submerging the vehicle 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.29 © Copyright Polaris Industries Inc.
Page 58 50/50 EL Anti-Free (Gal) (4 count) 2880513 50/50 EL Anti-Free (55 Gal Drum) 2880512 NOTE Each item can be purchased separately at your local Polaris dealer. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.30 © Copyright Polaris Industries Inc.
Page 59 MAINTENANCE 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) PS-4 Synthetic 4-Cycle Engine Oil (Quart)
Page 60 Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.32 © Copyright Polaris Industries Inc.
Page 61: Engine Maintenance
Lower the cargo box and secure in position. consistent. 5. Remove the dipstick and check the oil level. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.33 © Copyright Polaris Industries Inc.
Page 62 Ambient Temp Range: -35° F to 100° F PS-4 10W-40 Extreme Duty Full Synthetic Ambient Temp Range: 0° F to 120° F Capacity: 2.5 Qt. (2.4 L) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.34 © Copyright Polaris Industries Inc.
Page 63 Cylinder Leakage Service Limit: lock the lever. 21. Dispose of used oil and filter properly. If leakage exceeds service limit, inspect the engine for the cause. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.35 © Copyright Polaris Industries Inc.
Page 64 8. Measure the valve clearance using a feeler gauge. 5. Remove the four bolts and rubber isolators retaining the valve cover . Note the location and use of the grounding washer for assembly. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.36 © Copyright Polaris Industries Inc.
Page 65 Outer Clutch Cover Screws: 35 in-lbs (4 Nm) 17. Connect the negative (-) battery cable to the battery. 18. Start the engine to ensure proper operation. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.37 © Copyright Polaris Industries Inc.
Page 66 It should move freely. If it does not move freely, replace the tensioner assembly. 5. Retract the plunger all the way in and install into the cylinder. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.38 © Copyright Polaris Industries Inc.
Page 67 With the engine at operating temperature, the coolant level should be between the “MAX” and “MIN” marks on Polaris Premium 50/50 Extended Life coolant is already the recovery bottle. If not, perform the following: premixed and ready to use. Do not dilute with water.
Page 68 3. Check tightness and condition of all hose clamps. Do not over-tighten hose clamps at radiator, or radiator fitting may distort. TORQUE Coolant Hose Clamp: 35 in-lbs (4 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.40 © Copyright Polaris Industries Inc.
Page 69 MAX level. Refer to Cooling System Bleeding Procedure, page 3.91. FLUID CAPACITY Recommended Anti-Freeze/Coolant: Premium Pre-Mixed Extended Life Antifreeze (PN 2880514) (Quart) (PN 2880513) (Gallon) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.41 © Copyright Polaris Industries Inc.
Page 70 NOTE Make sure the hinge pins are properly seated when reassembling the airbox 3. Remove the air filter element 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.42 © Copyright Polaris Industries Inc.
Page 71 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 ft-lbs (11 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.43 © Copyright Polaris Industries Inc.
Page 72 Inspect Exhaust Heat Shields and make sure they are in good condition and are secured properly. ITEM DESCRIPTION Chassis Shield Headpipe Shield, Top Headpipe Shield, Bottom Silencer Outlet Shield, End Silencer Shield, Main Silencer Outlet Shield, Elbow 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.44 © Copyright Polaris Industries Inc.
Page 73 Refer to Fuel Pump Replacement, page 4.23 procedure. 3. Be sure fuel lines are routed and retained properly. NOTE Make sure lines are not kinked or pinched. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.45 © Copyright Polaris Industries Inc.
Page 74 Replace every two years. 2. Be sure vent line is routed properly and secured. NOTE Be sure vent line is not kinked or pinched. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.46 © Copyright Polaris Industries Inc.
Page 75 Access the drain plug through the left rear wheel well. 1. Using a flat blade screwdriver, remove the PVT drain plug and O-ring from the outer clutch cover. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.47 © Copyright Polaris Industries Inc.
Page 76 Transmission Fill / Drain Plug: specification. 10-14 lb-ft (14-19 Nm) TORQUE Transmission Fill / Drain Plug: 10-14 lb-ft (14-19 Nm) 8. Check for leaks. Dispose of used lubricant properly. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.48 © Copyright Polaris Industries Inc.
Page 77 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.49 © Copyright Polaris Industries Inc.
Page 78 7. Reinstall fill plug with a new O-ring and torque to specification. TORQUE Front Gearcase Fill / Drain Plug: 8-10 lb-ft (11-14 Nm) 8. Check for leaks. Dispose of used fluid properly. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.50 © Copyright Polaris Industries Inc.
Page 79 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.51 © Copyright Polaris Industries Inc.
Page 80: Tire Inspection
RANGER XP 1000 EDITION 10 psi / 69 kPa 14 psi / 96 kPa Front 14 psi / 96 kPa 16 psi / kPa Rear 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.52 © Copyright Polaris Industries Inc.
Page 81 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.53...
Page 82 • If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut). 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.54 © Copyright Polaris Industries Inc.
Page 83 Damage may not be immediately apparent if done incorrectly. • After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 13 ft-lbs (18 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.55 © Copyright Polaris Industries Inc.
Page 84 Shock Spanner Wrench: 2871095 4. Reinstall the upper shock mounting bolts and torque to specification. TORQUE Shock Mounting Bolts: 40 ft-lbs (54 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.56 © Copyright Polaris Industries Inc.
Page 85 Clean reservoir cover leakage around the master cylinder fittings and the thoroughly. brake caliper fittings. 2. Remove cover from reservoir. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.57 © Copyright Polaris Industries Inc.
Page 86 Torque bleed screw to specification. TORQUE Caliper Bleed Screws: 4 ft-lbs (5.5 Nm) Polaris DOT 4 Brake Fluid P/N: 14. Repeat Steps 9 - 13 for the remaining brake calipers. 2872189 15. Install master cylinder reservoir cover. 16. Field test machine at low speed before putting into 5.
Page 87 Replace disc if any are evident. 2. Use a 0-1" micrometer and measure disc thickness at 8 different points around perimeter of disc. Replace disc if worn beyond service limit. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.59 © Copyright Polaris Industries Inc.
Page 88 “Charging Procedure” provided in Chapter 10. Do not use the vehicle’s stator/alternator to charge a new battery. 4. Disconnect the red (positive) battery cable 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.60 © Copyright Polaris Industries Inc.
Page 89 4. Inspect the engine ground terminals. Be sure they are clean and tight. TORQUE Battery Bracket Fastener: 3.5 ft-lbs (5 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.61 © Copyright Polaris Industries Inc.
Page 90 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.62 © Copyright Polaris Industries Inc.
Page 91 Be sure the throttle pedal returns normally when released. Refer to PPS Test, page 4.36 procedure if experiencing a lack of throttle response. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 2.63 © Copyright Polaris Industries Inc.
Page 97 2870975 Oil Filter Oil Filter Wrench PU-50105 PN 2540086 Oil Pressure Gauge PV-43531 Oil Pressure Minimum Specification (using Polaris Oil Pressure Gauge Adapter PU-52492 engine oil at operating temperature) 10 PSI @ 1200 RPM Piston Ring Compressor Pliers PV-43570-1 40 PSI @ 7000 RPM...
Page 98 NOTE Test results are based on the use of the recommended engine oil (Polaris PS-4 or PS-4 Extreme Duty) at operating temperature, and may vary considerably if any other oil is used or if engine is not up to temperature.
Page 100 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 101 Valve Seat - Contacting Width - Exhaust .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° 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 102 Less than .001″ Crankshaft Runout Limit (PTO and MAG) (0.025 mm) Balance Bearing Journal O.D. (Standard) 1.4939 - 1.4946" (37.946 - 37.962 mm) 1.4921" (37.900 mm) Shaft 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.10 © Copyright Polaris Industries Inc.
Page 103 M6 Bolts: M6 Bolts: 9 ft-lbs (12 Nm) VALVE COVER CAM CARRIER Camshaft Carrier Bolts Valve Cover Bolts 7 ft-lb (10 Nm) 7 ft-lbs (10 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.11 © Copyright Polaris Industries Inc.
Page 104 Step 4: M6 bolts: 7 ft- lb (10 Nm) STATOR COVER OIL COOLER Stator Cover Bolts Oil Cooler 9 ft-lbs (12 Nm) 18 ft-lb (24 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.12 © Copyright Polaris Industries Inc.
Page 105 INTAKE SYSTEM ASSEMBLY VIEW TORQUE ITEM DESCRIPTION Fresh Air Intake Line Engine Intake Elbow Clutch Intake Elbow Intake Duct Clamps 35 in-lbs (4 Nm) Intake Hard Line 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.13 © Copyright Polaris Industries Inc.
Page 106 Airbox Mount Fastener Air Filter Airbox Cover Intake Hard Line Vent Hose Airbox to Engine Tube Engine Intake Housing Intake Duct Clamps 35 in-lbs (4 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.14 © Copyright Polaris Industries Inc.
Page 107 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.15 © Copyright Polaris Industries Inc.
Page 108 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.16 © Copyright Polaris Industries Inc.
Page 109 17 in-lbs (2 Nm) 5. Torque Lower Intake Plenum Fastener specification. TORQUE Lower Intake Plenum Fastener: 18 ft-lbs (24 Nm) 9. Secure harness mounting clips in mounting tabs. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.17 © Copyright Polaris Industries Inc.
Page 110 Procedure, page 4.27, connecting battery as needed. 13. Inspect engine while running to watch for any fuel leaks. 14. Perform Cargo Box Installation, page 10.24. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.18 © Copyright Polaris Industries Inc.
Page 111 Exhaust Stud w/Spring 21 ft-lbs (28 Nm) Exhaust Head Pipe Mounting Bolts 18 ft-lbs (24 Nm) Head Pipe Gasket 10 ft-lbs (14 Nm) Muffler Mount Fasteners 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.19 © Copyright Polaris Industries Inc.
Page 112: Engine Service
Torque fasteners specification. TORQUE Isolator Bolts: 40 ft-lbs (54 Nm) Engine Mount Isolator Nuts: 22 ft-lbs (30 Nm) Skid Plate Fasteners: 6 ft-lbs (8 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.20 © Copyright Polaris Industries Inc.
Page 113 DO NOT remove large heat shield secured to the close off panel. IMPORTANT Place a shop towel around the fuel line to catch any dripping fuel. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.21 © Copyright Polaris Industries Inc.
Page 114 Make note of Hose Clamps orientation for installation. 2. Drain engine coolant. Refer to Coolant Replacement, page 2.41. 14. Remove lower manifold mounting bolt (to trans mount bracket). 3. Disconnect the battery. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.22 © Copyright Polaris Industries Inc.
Page 115 6. Disconnect the two AC lines on the back of the AC compressor. 9. Remove clamps at engine water pump. Remove hoses from water pump. 10. Refer to Engine Removal, page 3.21 for next steps. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.23 © Copyright Polaris Industries Inc.
Page 116 STEP 6: Torque to 50 ft-lb (68 Nm) STEP 7: Loosely install nuts by hand STEP 8: Torque to 50 ft-lb (68 Nm) STEP 9: Torque to 37 ft-lb (50 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.24 © Copyright Polaris Industries Inc.
Page 117 Starter Cable Wiring Nuts: 48 in-lbs (5 Nm) TORQUE Intake Manifold Boot Clamp: 17 in-lbs (2 Nm) Lower Intake Plenum Fastener: 18 ft-lbs (24 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.25 © Copyright Polaris Industries Inc.
Page 118 24. Fill coolant reservoir. Bleed system as required. See Cooling System Bleeding Procedure, page 3.91. 25. Check and fill engine oil as required. See Engine Oil and Filter Replacement, page 2.34. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.26 © Copyright Polaris Industries Inc.
Page 119 Cooling System Bleeding Procedure, page 3.91. 8. Check and fill engine oil as required. See Engine Oil and Filter Replacement, page 2.34. 9. Connect battery. Torque fasteners specification. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.27 © Copyright Polaris Industries Inc.
Page 120 10. Recharge the AC system. Refer to Reclamation and Charging with Recovery / Charging Unit, page 3.111 and Refrigerant, page 3.110 for procedure and sys- tem capacity. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.28 © Copyright Polaris Industries Inc.
Page 121 Center (TDC) to relieve most of the valve spring pressure. The camshaft lobes should face out the slots on the end of the camshafts should line up. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.29 © Copyright Polaris Industries Inc.
Page 122 10. Mark the intake and exhaust camshafts to ensure proper assembly. 11. Carefully remove camshafts from the cylinder head. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.30 © Copyright Polaris Industries Inc.
Page 123 1.5142 - 1.5181" (38.46 - 38.56 mm) 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) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.31 © Copyright Polaris Industries Inc.
Page 124 Plate (PU-50563). Refer to Cylinder / Piston Removal, page 3.51 procedure. Necessary Subsequent Procedures 1. Check Engine Timing Camshaft Timing - Quick Refer- ence, page 3.80 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.32 © Copyright Polaris Industries Inc.
Page 125 If warp exceeds the service limit, replace the cylinder head. MEASUREMENT Cylinder Head Warp Limit: .0039″ (0.1 mm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.33 © Copyright Polaris Industries Inc.
Page 126 8. Clean the combustion chamber and head gasket surface. 9. Check the condition of each valve spring. Replace if wear or cracking is present on the spring. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.34 © Copyright Polaris Industries Inc.
Page 127 .2165 - .2171" (5.500 - 5.515 mm) 7. Be sure to measure each guide and valve combination individually. NOTE The valve guides cannot be replaced. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.35 © Copyright Polaris Industries Inc.
Page 128 2. Visually inspect cylinder head gasket surface and combustion chamber for cracks or damage. Pay close attention to areas around spark plug and valve seats. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.36 © Copyright Polaris Industries Inc.
Page 129 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.37 © Copyright Polaris Industries Inc.
Page 130 .0393 ± .0039" (1.0 ± 0.10 mm) Service Limit: .0551" (1.4 mm) Exhaust: .0590 ± .0039" (1.5 ± 0.10 mm) Service Limit: .0748" (1.9 mm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.38 © Copyright Polaris Industries Inc.
Page 132 3. Inspect the condition of the stator windings output wires . If replacement is required, refer to the Electrical chapter. 4. Inspect the ball bearing that supports the starter motor shaft. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.40 © Copyright Polaris Industries Inc.
Page 133 Leave them all attached to the water pump housing. 2. Remove the three long gold colored bolts retaining the water pump housing to the engine. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.41 © Copyright Polaris Industries Inc.
Page 134 Way Clutch Disassembly, page 3.43 procedure. 5. Fully install Flywheel Puller (PA-49316) on the threads of the flywheel (left hand thread - turn flywheel puller counterclockwise to install). 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.42 © Copyright Polaris Industries Inc.
Page 135 3. Remove the one-way clutch and inspect both sides of drive rollers . Inspect the roller contact surface inside the hub for wear, damage or uneven surface. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.43 © Copyright Polaris Industries Inc.
Page 136 The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 5. Rotate engine to access the crankcase sump cover. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.44 © Copyright Polaris Industries Inc.
Page 137 13. Rotate the engine so the cylinder is facing up. 14. Remove the eleven M6 and two M8 upper crankcase bolts. 15. Rotate the engine so the cylinder is facing down. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.45 © Copyright Polaris Industries Inc.
Page 138 3. Carefully rotate the balance shaft and remove it from the crankcase. 4. Inspect the balance shaft gear teeth for damage. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.46 © Copyright Polaris Industries Inc.
Page 139 5. Carefully lift the crankshaft out of the crankcase. 6. Remove the cam chain , oil pump drive chain and PTO main seal from the crankshaft. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.47 © Copyright Polaris Industries Inc.
Page 140 Less than .001″ (0.025 mm) 10. Visually inspect surface of crankshaft main and connecting rod journals. Replace crankshaft if any journal is scratched or pitted. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.48 © Copyright Polaris Industries Inc.
Page 141 14. Whether installing a new crankshaft or re-installing the original, refer to the bearing selection chart provided “Crankshaft Main Bearing Selection”, page 3.58 and “Connecting Rod Bearing Selection”, page 3.58 procedures. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.49 © Copyright Polaris Industries Inc.
Page 142 DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing. 3. Inspect taper and out of round with a dial bore gauge. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.50 © Copyright Polaris Industries Inc.
Page 144 DO NOT apply heat to piston rings or a loss of radial MEASUREMENT tension could result. Piston Pin O.D.: .7873 - .7875" (20.000 - 20.005 mm) Service Limit: .7866" (19.98 mm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.52 © Copyright Polaris Industries Inc.
Page 146 Oil Control Rails: .008 - .028" (0.20 - 0.70 mm) Service Limit: .0354" (0.9 mm) NOTE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.54 © Copyright Polaris Industries Inc.
Page 147 (and matching rod cap) for damage, galling of surface or pitting. 8. Refer to the number stamped onto the exhaust side of the connecting rod. This number represents the bore diameter. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.55 © Copyright Polaris Industries Inc.
Page 148 10. Whether using new connecting rods or re-installing the original ones, refer to the bearing selection chart provided “Connecting Bearing Selection”, page 3.58 procedure in this chapter. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.56 © Copyright Polaris Industries Inc.
Page 149 Letters (six letters) *Some engines may only have 4 digits. The extra two digits will refer to the balance shaft bearings which should now all be standard. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.57 © Copyright Polaris Industries Inc.
Page 150 Bearing Selection Chart — Main Bearings Blue Blue Green Blue Green Yellow Crankshaft Green Yellow Yellow Code Blue Blue Green Case Blue Green Yellow Green Yellow Yellow 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.58 © Copyright Polaris Industries Inc.
Page 151 (see illustration below). NOTE Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.59 © Copyright Polaris Industries Inc.
Page 152 4. Install second ring with marking facing top of piston. Rotate ring to position the end gap toward intake side of piston as shown below. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.60 © Copyright Polaris Industries Inc.
Page 153 (there is no piston pin offset in the rod), however it is recommended they be installed with rods facing the same direction. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.61 © Copyright Polaris Industries Inc.
Page 154 10. Carefully place the cylinder and pistons into the upper crankcase. NOTE Orientation arrow is also located on the bottom side of piston as an additional reference. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.62 © Copyright Polaris Industries Inc.
Page 155 11. Install the Cylinder Holding & Camshaft Timing Plate (PU-50563) onto the cylinder. The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.63 © Copyright Polaris Industries Inc.
Page 156 ENGINE / COOLING / EXHAUST CRANKSHAFT INSTALLATION 6. Apply Polaris PS-4 engine oil to each rod bearing journal and main bearing journal of crankshaft. NOTE Whether installing a new crankshaft or re-installing the original, refer to the bearing selection charts in the “Crankshaft Main Bearing Selection”, page 3.58 and...
Page 157 Press bearing insert firmly into place. 13. Install new bolts and tighten evenly until snug. 3. Apply Polaris PS-4 engine oil to both balance shaft journals 14. Torque connecting rod bolts to specification. TORQUE 4.
Page 158 6. Flush all oil passages with solvent and then warm soapy water. Rinse with clear, warm water and dry with compressed air. 7. Be sure passages are clean and dry before assembling the crankcase. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.66 © Copyright Polaris Industries Inc.
Page 159 8. Inspect crankcase mating surfaces to be sure they are joined properly. Investigate the cause of any gaps. 3. Apply Polaris PS-4 engine oil to the new bearings 9. Install the eight M10 , two M8 and one M6 installed in the lower crankcase half.
Page 160 11. Rotate the engine so the cylinder is facing up. 12. Install the eleven M6 and two M8 upper crankcase bolts. Tighten all bolts lightly by hand. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.68 © Copyright Polaris Industries Inc.
Page 162 25. Install the crankcase drain plug if previously removed. Torque drain plug to specification. TORQUE Crankcase Drain Plug: 12 ft-lbs (16 Nm) 26. Install the oil cooler . Use new O-rings upon installation. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.70 © Copyright Polaris Industries Inc.
Page 163 One Way Clutch Asm. Torque Limit Gear Asm. Flywheel Retaining Bolt Step 1: 133 ft-lbs (180 Step 2: Back out bolt 180° & retorque to spec. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.71 © Copyright Polaris Industries Inc.
Page 164 7. Wipe off excess Loctite and let stand for 1 hour before starting engine. NOTE Loctite cures with time, the longer the unit is let stand before engine starting the better the joint will be. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.72 © Copyright Polaris Industries Inc.
Page 165 To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers. 9. Install split keepers with gap even on both sides. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.73 © Copyright Polaris Industries Inc.
Page 166 Once the cylinder head is removed, nothing retains the cylinder to the engine. DO NOT rotate the engine without using the Cylinder Holding & Camshaft Timing Plate (PU-50563). 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.74 © Copyright Polaris Industries Inc.
Page 167 Torque in sequence Step 1: 13 ft-lbs (18 Nm) Step 2: 26 ft-lb (35 Nm) Step 3: Additional 180° Step 4: M6 bolts: 7 ft-lb (10 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.75 © Copyright Polaris Industries Inc.
Page 168 3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to 8. Verify the TDC mark on the flywheel is still properly installation.
Page 169 (see Step 1) and cam sprocket sprocket . Do not torque the bolts at this time. markings should line up as shown. NOTE Use new sprocket retaining bolts upon assembly. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.77 © Copyright Polaris Industries Inc.
Page 170 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 • Retract the plunger all the way in and install into the cylinder.
Page 171 ENGINE / COOLING / EXHAUST 23. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.79 © Copyright Polaris Industries Inc.
Page 172 DO NOT use the “V” mark located on the flywheel opposite of the “I” mark. Only the “I” mark should be used as a TDC reference 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.80 © Copyright Polaris Industries Inc.
Page 173 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 3-digit tappet number. 13. Refer to the appropriate tappet selection matrix (Intake or Exhaust) on the following pages and select the proper tappet. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.82 © Copyright Polaris Industries Inc.
Page 175 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.83 © Copyright Polaris Industries Inc.
Page 176 T40 driver. 6. Torque valve cover bolts to specification. TORQUE Spark Plugs: 9 ft–lbs (12 Nm) Valve Cover Bolts: 7 ft-lbs (10 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.84 © Copyright Polaris Industries Inc.
Page 177 Radiator Oil Cooler Outlet Hose Engine Hoses Pressure Cap Bypass Hose Lower Radiator Hose Upper Radiator Hose Water Pump Outlet Hose Fan Assembly Recovery Bottle 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.85 © Copyright Polaris Industries Inc.
Page 178 Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
Page 179 (commercially available). 3. The pressure cap relief pressure is 13 psi. Replace cap if it does not meet this specification. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.87 © Copyright Polaris Industries Inc.
Page 180 7. Remove four fasteners securing the radiator fan to the radiator. Separate the fan motor assembly from the radiator. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.88 © Copyright Polaris Industries Inc.
Page 181 Upper Radiator Hose To Radiator Fitting Lower Radiator Hose Fan Motor Assembly Recovery Bottle Radiator 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.89 © Copyright Polaris Industries Inc.
Page 182 6. Remove the cargo box access panel. 7. Using an 8 mm swivel socket and long extension, remove the front bolt retaining the thermostat cover. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.90 © Copyright Polaris Industries Inc.
Page 183 1. Allow engine and cooling system to cool down. 4. Remove the pressure cap and add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck. 5. Tilt the rear cargo box to the raised position. 6. Remove the upper exhaust heat shield to access the coolant bleed screw.
Page 184 11. Remove the pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck. 12. Open the bleed screw to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.
Page 185 10. Remove the five coolant hoses that are attached to the water pump. Note location and routing for installation. Be sure to catch and dispose of coolant properly. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.93 © Copyright Polaris Industries Inc.
Page 187 16. Install the hood and seats. NOTE The water pump impeller bolt is left hand thread (reverse thread). 5. Remove impeller from water pump shaft. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.95 © Copyright Polaris Industries Inc.
Page 188 12. Fully install the water pump shaft and two washers into the housing. 13. Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.96 © Copyright Polaris Industries Inc.
Page 189 22. Install water pump assembly into engine. Water Pump Assembly View Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.97 © Copyright Polaris Industries Inc.
Page 190 • Cylinder, piston, ring, or valve wear or damage (check compression) • PVT not operating properly • Restricted exhaust muffler • Cam worn excessively Piston Failure - Scoring 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.98 © Copyright Polaris Industries Inc.
Page 191 • Thermostat stuck open Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.99 © Copyright Polaris Industries Inc.
Page 192 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.100 © Copyright Polaris Industries Inc.
Page 193 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.101 © Copyright Polaris Industries Inc.
Page 194 12 ft-lbs (16 Nm) EVAPORATOR HEATER RETURN HOSE HEATER SUPPLY HOSE AC SUCTION HOSE HVAC MOUNTING WASHER HVAC MOUNTING FASTENER 8 ft-lbs (11 Nm) MAIN HVAC ASSEMBLY 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.102 © Copyright Polaris Industries Inc.
Page 195 FILTER SUPPORT FASTENER 18 in-lbs (2 Nm) AIR FILTER AIR FILTER BAND CLAMP 24 in-lbs (3 Nm) CENTER DASH DUCTING ASSEMBLY DEFROST VENT DUCTING ASSEMBLY, LH 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.103 © Copyright Polaris Industries Inc.
Page 199 A/C for defrost of the windows and temperature control. Heater Valve: The heater valve is used to control the amount of engine coolant that flows to the heater coil. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.107 © Copyright Polaris Industries Inc.
Page 200 2. Tilt the rear cargo box to the upright position. specified belt can shorten the belt life. 3. Disconnect the upper duct 4. Remove the fasteners holding the alternator cover to the vehicle. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.108 © Copyright Polaris Industries Inc.
Page 201 4. Remove the two push rivets retaining the condenser cover. 7. Reassemble vehicle. 5. Tilt the condenser cover upwards on the folding crease to gain access to the condenser. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.109 © Copyright Polaris Industries Inc.
Page 202 System Capacity: R134a 1.6 lbs (.726 kg) 2. Remove the hood and the cabin air filter. 3. Clean the filter with low air pressure. Check for damage, replace if damaged. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.110 © Copyright Polaris Industries Inc.
Page 204 6. Loosen the three alternator fasteners enough to slide the alternator outward with enough room for the compressor drive belt to slide belt. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.112 © Copyright Polaris Industries Inc.
Page 205 Alternator Cover Fasteners: 48 lb-in (5.4 Nm) 15. Install the outer alternator cover and torque the fasteners to specification. TORQUE Alternator Cover Fasteners: 48 lb-in (5.4 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.113 © Copyright Polaris Industries Inc.
Page 207 . Add 150 - 170 cc's of PAG 100 oil. NOTE The suction port on the compressor is marked with an S and is the larger. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.115 © Copyright Polaris Industries Inc.
Page 208 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) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.116 © Copyright Polaris Industries Inc.
Page 209 HVAC Drive Pulley Fastener: 44 lb-ft (60 Nm) + 180° 6. If necessary, remove the fasteners holding the timing wheel and adapter hub to the engine. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.117 © Copyright Polaris Industries Inc.
Page 210 4. Remove the two push rivets retaining the condenser cover. 7. Remove the two push rivets retaining the shroud and lift the shroud straight up to remove. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.118 © Copyright Polaris Industries Inc.
Page 211 2. Reinstall the two condenser retaining fasteners NOTE Receiver Drier is contained within the condenser and is not replaced separately. 3. Install the front shroud and two push rivets 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.119 © Copyright Polaris Industries Inc.
Page 212 18 ft-lbs (24 Nm) 7. Reinstall the hood panel and lock the 1/4 turn fasteners. Reinstall the condenser cover 5. Install both push rivets retaining the condenser cover. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.120 © Copyright Polaris Industries Inc.
Page 213 5. Cap and plug the hoses and the expansion valve to specification. fittings with the proper A/C caps and plugs. TORQUE HPCO Switch: 6 ft-lb (8 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.121 © Copyright Polaris Industries Inc.
Page 214 22 ft-lb (30 Nm) 8. Recharge the A/C system. 6. Remove the clamps holding the coolant hoses to the heater / evaporator unit through the front wheel opening. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.122 © Copyright Polaris Industries Inc.
Page 215 Air Distributor Manifold Fasteners: TORQUE 18 in-lbs (2 Nm) Heater / Evaporator Unit Mounting Fasteners: 10 lb-ft (14 Nm) 5. Reinstall the blower unit connector. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.123 © Copyright Polaris Industries Inc.
Page 216 / evaporator unit top cover. 5. For installation, reverse removal procedure. Tighten heater coil mounting fasteners until fully secure. 6. Recharge the A/C system. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.124 © Copyright Polaris Industries Inc.
Page 217 The EDT will attempt to restart every 20 seconds until the fault is repaired. 6. Fill and bleed cooling system. Refer to Cooling System Bleeding Procedure, page 3.91 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.125 © Copyright Polaris Industries Inc.
Page 218 1. Disconnect the harness going to the Fan Switch. 2. With the meter in the ohms mode, place the meter leads onto the switch contacts. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.126 © Copyright Polaris Industries Inc.
Page 220 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.128 © Copyright Polaris Industries Inc.
Page 221 System pressures equal 1. Clutch not operating. See compressor clutch related topics above. 2. Compressor not Equal high and low pressures. Replace compressor. pumping. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.129 © Copyright Polaris Industries Inc.
Page 222 Example: Ambient Temperature = 90ºF 90ºF + 40ºF = 130ºF condenser temperature / 200 PSIG Conditions and pressures will vary from system to system. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.130 © Copyright Polaris Industries Inc.
Page 223 High A/C position. 8. Replace the heater valve. 2. Start the utility vehicle and run at high idle, for ten minutes. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 3.131 © Copyright Polaris Industries Inc.
Page 227 • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 228 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 229 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 230 • Fuel Rail / Supply Line • Ignition Coil • Intake Plenum • Pedal Position Sensor (PPS) • Temp / Manifold Absolute Pressure Sensor (T-MAP) • Wire Harness Assembly 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 231 6. Pedal Position Sensor (PPS) 3. Crankshaft Position Sensor (CPS) - Located on the side of the throttle pedal assembly. - Located on top of the stator cover. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 232 - Located on the intake plenum, on top of the fuel injectors. 9. Fuel Supply Line - Connected to the left end of the fuel rail and top of the fuel pump. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 233: Fuel Lines
. The fuel line then continues under the clutch outlet duct where it connects to the fuel rail. NOTE Image orientation is from the rear driver-side of the vehicle with the cargo box in the raised position. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 234 Fuel Line Routing, page 4.9. 3. Disconnect the fuel line connector securing the fuel line to the clutch. 4. Pull the fuel line outward to remove. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.10 © Copyright Polaris Industries Inc.
Page 236 Image orientation is from the front passenger-side of the vehicle NUMBER PART DESCRIPTION Evaporative Emissions Canister Canister Filter Vent Line Termination Fitting Purge Line Routing Clip Purge Line Purge Valve 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.12 © Copyright Polaris Industries Inc.
Page 237 If the vent line fitting is removed from the frame, it must be replaced. The ears on the clip (arrows) will not hold properly once it is removed. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.13 © Copyright Polaris Industries Inc.
Page 238 Do not over-pry or excessively bend the retaining tabs. This can damage the retaining clip, and require replacement of the fuel line assembly. 5. Push retaining clip upward into the open position. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.14 © Copyright Polaris Industries Inc.
Page 239 4. Quick connect has been twisted from its original inserted position, or the connector has been damaged. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.15 © Copyright Polaris Industries Inc.
Page 240 Fuel Tank Asm Tank Vent / Rollover Valve Fuel Inlet Fuel Pump / Regulator Fuel Cap Fuel Level Float Arm Gasket Preliminary Fuel Filter Fuel Sender Nut 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.16 © Copyright Polaris Industries Inc.
Page 241 8. Remove the two fuel tank bracket fasteners that retain the fuel tank in the chassis. Swing the tank brackets clear of the fuel tank for removal. 4. Install fuel cap. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.17 © Copyright Polaris Industries Inc.
Page 242 5. Reconnect the fuel pump electrical harness. 6. Install the fuel line and vent line, and verify they are secure. 7. Install driver-side body panel. Torque fasteners to specification. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.18 © Copyright Polaris Industries Inc.
Page 243 3.5 ft-lbs (5 Nm) 9. Install Battery. Install Battery Bracket and Battery Bracket Fastener Torque Fastener specification. TORQUE Battery Bracket Fastener: 3.5 ft-lbs (5 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.19 © Copyright Polaris Industries Inc.
Page 244 FUEL SYSTEM 12. Install Driver Seat. • Engage front seat base tabs. • Push seat down until properly seated. 13. Fold down passenger seat. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.20 © Copyright Polaris Industries Inc.
Page 245 • Bent float rod 6. If none of the conditions exist, the fuel sender assembly is faulty. Replace the fuel pump assembly. Refer to Fuel Pump Replacement procedure. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.21 © Copyright Polaris Industries Inc.
Page 246 “3” and “4”' at the white fuel pump connector to check for continuity within the fuel pump. NOTE If there was no continuity between the pump terminals, replace the fuel pump assembly. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.22 © Copyright Polaris Industries Inc.
Page 247 5. While holding a shop towel over the fuel line connector, disconnect the fuel supply line from the pump. Refer to Fuel Line Removal / Installation, page 4.10 procedure. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.23 © Copyright Polaris Industries Inc.
Page 248 14. Install fuel pump into fuel tank, hold float arm to the pump body and tilt assembly to ensure float arm does not get caught or bent during installation. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.24 © Copyright Polaris Industries Inc.
Page 249 Verify orientation marks are still aligned between fuel pump and fuel tank. 18. Torque nut to specification using the Fuel Pump Service Tool (PU-50326) and a calibrated torque wrench. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.25 © Copyright Polaris Industries Inc.
Page 250 For the purpose of troubleshooting, a known-good ECU and determines the appropriate fuel and ignition from another Polaris RANGER Fullsize 570 / XP 900 of requirements for the immediate operating conditions. the same model may be used without system or engine The ECU then sends output signals to set injector component damage.
Page 251 7. To reinstall, reverse this procedure and tighten the mounting screws to specification. NOTE Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.27 © Copyright Polaris Industries Inc.
Page 252 All operating and control functions within the ETC are pre-set. 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 not replace the ETC without factory authorization.
Page 254 Remove the component it is mounted to, remove the connector, and disengage the switch from the panel by depressing the retention tabs. Reverse to install. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.30 © Copyright Polaris Industries Inc.
Page 255 Inspect CPS and flywheel encoder ring for damage. Refer to CPS REPLACEMENT procedure. 4. If the resistance is incorrect, follow the CPS REPLACEMENT procedure. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.31 © Copyright Polaris Industries Inc.
Page 256 9 ft-lbs (12 Nm) 7. Route CPS wire lead through wire clip reconnect CPS harness connector NOTE Make sure CPS harness connector standoff remains properly secured. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.32 © Copyright Polaris Industries Inc.
Page 257 T-MAP Retaining Fastener: faulty, it must be replaced. 3 ft-lbs (4.5 Nm) NOTE This sensor should only be tested using the Digital Wrench® Diagnostic Software (dealer only). 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.33 © Copyright Polaris Industries Inc.
Page 258 Refer to COOLANT TEMPERATURE SENSOR 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 259 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.35 © Copyright Polaris Industries Inc.
Page 260 Pedal WOT 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.36 © Copyright Polaris Industries Inc.
Page 261 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.37 © Copyright Polaris Industries Inc.
Page 262 Line Removal / Installation, page 4.10 procedure. 7. Disconnect the fuel injector harness leads. 8. Remove the two fuel rail fasteners that mount the fuel rail to the intake plenum. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.38 © Copyright Polaris Industries Inc.
Page 264 4. Connect the harness going to the oxygen sensor. CONNECTOR WIRE PIN AND WIRE COLOR CONNECTION Gray Sensor Ground Sensor Output Black White Heater Power White Heater Ground 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.40 © Copyright Polaris Industries Inc.
Page 265 MODE button or turn the ignition key OFF once the codes are recorded. 2. Press and hold the MODE button to enter the diagnostics code menu. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.41 © Copyright Polaris Industries Inc.
Page 266 Driver Circuit Short to B+ P0265 Driver Circuit Grounded P1265 Driver Circuit Open / Grounded P1691 Rear Differential Output Driver Circuit Short to B+ P1692 Driver Circuit Grounded P1693 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.42 © Copyright Polaris Industries Inc.
Page 267 C1054 EPS Inverter Temperature 520225 Greater than 120° C (248° F) C1055 EPS CAN Communications No RX Message for 2 Seconds 520226 U0100 Receive Error 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.43 © Copyright Polaris Industries Inc.
Page 268 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.44 © Copyright Polaris Industries Inc.
Page 269 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.45 © Copyright Polaris Industries Inc.
Page 270 • Wiring to the Crankshaft Position Sensor, ECU and Ignition Coil are not damaged. Chassis ground is clean and tight • Fuel pressure is within specification 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.46 © Copyright Polaris Industries Inc.
Page 271 • Poor fuel quality (old fuel) • Spark plug(s) fouled • Fouled spark plug • Spark plug wires loose or worn • Injector failure • Faulty electrical connection 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.47 © Copyright Polaris Industries Inc.
Page 272: Special Tools
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 273 ‘Connected’ in the lower left corner of the screen. 5. Once connected, proceed with using Digital Wrench®. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.49 © Copyright Polaris Industries Inc.
Page 274 Wrench® start-up screen. 4. The Digital Wrench® portal website should appear in a new web browser. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.50...
Page 275 NOTE Do not "run" or "open" the file from where they are. Select "save" and download them to your PC before running the install. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.51 © Copyright Polaris Industries Inc.
Page 277 Special Tests menu icon (red tool box). A technician should be familiar with the process and with • Proceed to http://polaris.diagsys.com for specific computer operation in general before attempting to information and FAQs on how to troubleshoot reprogram an ECU.
Page 278 5. Select the “Special Tests” icon. NOTE Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen. 6. Select “Engine Controller Reprogramming”. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.54 © Copyright Polaris Industries Inc.
Page 279 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 4.55 © Copyright Polaris Industries Inc.
Page 280 (PMDW) menu. • Only CAN-based vehicles are compatible with PMDW Polaris Mobile Digital Wrench (PMDW) is a diagnostic and the WVL. A complete list of compatible vehicles software application (app) designed specifically for can be found in the user’s guide.
Page 283 (initial vehicle movement), 5020635 Bushing Replacement Tool clutch upshift and backshift. During the development of the Polaris vehicle, the PVT system is matched first to the Roller Pin Tool 2870910 engine power curve; then to average riding conditions Universal Clutch Compressor vehicle’s...
Page 284 (42.993 mm) Vespel® Thrust 0.030 – 0.040” 0.020” (0.50 Washer (0.76 - 0.96 mm) Thickness Drive Clutch Helix Greater than 0.146” (3.71 Thickness 0.146” (3.71 mm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 285 Rather than vary throttle position, as a conventional governor does, the PVT system changes engine load requirements by either upshifting or backshifting. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 287 5.35 chart at the end of this chapter for possible 5. Mark the drive belt direction of rotation so that it can causes. be installed in the same direction. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 288 6. Rotate clutch cover over A-Arm as shown. Use PVT Outer Cover Fasteners care not to damage intake boots or electrical harness. 35 in-lbs (4 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 289 IMPORTANT Ensure the driven clutch taper and transmission taper are clean and free of debris. 7. Reinstall the washers and Driven Clutch Bolt. Torque to specification. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 290 SEAL, INLET DUCT 35 in-lbs (4 Nm) PVT INLET HOSE CLAMP OUTLET DUCT PVT HOSE JOINT 54 in-lbs (6 Nm) OUTLET DUCT FASTENERS REAR FENDER INTAKE 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.10 © Copyright Polaris Industries Inc.
Page 291 PVT Inlet Duct Fasteners 4. Reinstall duct and fasteners . Torque to 54 in-lbs (6 Nm) specification. TORQUE PVT Outlet Duct Fasteners 54 in-lbs (6 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.11 © Copyright Polaris Industries Inc.
Page 292 Remove the outer slip fit 4. Remove the drive belt. Refer to Belt Removal, page post in order to insert the Drive Clutch holding tool. 5.6. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.12 © Copyright Polaris Industries Inc.
Page 293 The transmission will need to be lowered until sufficient clearance is gained to remove the lowest mounting bolt 13. Remove the inner clutch cover from the vehicle. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.13 © Copyright Polaris Industries Inc.
Page 294 . Do not torque. 9. Torque the two fasteners 6. Insert the two fasteners through the transmission. TORQUE Clutch Cover Fasteners 50 ft-lbs (68 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.14 © Copyright Polaris Industries Inc.
Page 295 Input Shaft without the Driven Clutch being fully mated to the Input Shaft. Damage can occur to the clutch and Input Shaft if the Driven Clutch is not flush with the Input Shaft. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.15 © Copyright Polaris Industries Inc.
Page 296 20. Install the PVT inlet duct hose. Torque the hose clamp to specification. TORQUE Driven Clutch Retaining Bolt: 43 lb-ft (58 Nm) 18. Install the Drive Clutch Stationary Sheave. Ensure the Sheave is fully seated 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.16 © Copyright Polaris Industries Inc.
Page 297 25. Install the intake duct. Torque the intake duct clamps to specification. Install the breather hose and clamp. TORQUE PVT Duct Hose Clamps: 35 in-lbs (4 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.17 © Copyright Polaris Industries Inc.
Page 298 Dome side facing outer post Washer Spider Sheave Assembly Bushing EBS Spring One Way Clutch Spacer Spacer Flange Orientation as shown Bushing Sleeve Clutch Washers 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.18 © Copyright Polaris Industries Inc.
Page 299 Ensure EBS cam is fully matted Drive Helix Stationary Sheave Shift Weight Clutch Button Clutch Spider Roller Washer Spider Roller Spider Pin Weight Bushing Must not protrude once seated 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.19 © Copyright Polaris Industries Inc.
Page 300 3. Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or damaged. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.20 © Copyright Polaris Industries Inc.
Page 301 IMPORTANT Do not pull on the outer fingers of the spider or damage may occur. Position 3 jaw puller in the positions shown 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.21 © Copyright Polaris Industries Inc.
Page 302: Clutch Inspection
A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. Refer to Roller, Pin, and Thrust Washer Inspection, page 5.21 procedure. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.22 © Copyright Polaris Industries Inc.
Page 303 Measure the free length of the spring and compare to beyond specification. specification. Replace if necessary. MEASUREMENT MEASUREMENT Helix Service Limit EBS Spring Free Length 0.146” (3.71 mm) 0.76 in (17.78 mm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.23 © Copyright Polaris Industries Inc.
Page 304 Replace the drive clutch assembly if shaft is worn or damaged. MEASUREMENT Drive Clutch Spring Height: 3.76 in (95.43 mm) MEASUREMENT Shaft Diameter: 1.413” (35.913 mm) Service Limit:1.416” (35.975 mm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.24 © Copyright Polaris Industries Inc.
Page 305 9. Remove nut from puller rod and set aside. 10. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.25 © Copyright Polaris Industries Inc.
Page 306 5. Turn clutch cover counterclockwise on puller rod until bushing is seated. 6. Remove nut from puller rod. Take installation tool and clutch cover off rod. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.26 © Copyright Polaris Industries Inc.
Page 307 Stationary Sheave. IMPORTANT During reassembly ensure the EBS cam remains fully seated with the Stationary Sheave or EBS cam damage and severe creeping will occur. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.27 © Copyright Polaris Industries Inc.
Page 308 6. Install the clutch cover and clutch cover bolts Hand tighten bolts. 7. Install cover bolts and torque in a cross pattern evenly to specification. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.28 © Copyright Polaris Industries Inc.
Page 309 Drive Clutch Bolt: 96 ft-lbs (130 Nm) 8. Install drive clutch assembly and drive clutch bolt Use drive clutch holding tool. Drive Clutch Holding Fixture PU-52430 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.29 © Copyright Polaris Industries Inc.
Page 310 Helix Bushing Spring Spring Cup Bushing Moveable Sheave 32 ft-lbs (44 Nm) Helix Fasteners E-Clip Fully Seat in Grooves Roller Washer Roller Pin Spring Pin 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.30 © Copyright Polaris Industries Inc.
Page 311 (helix) assembly using a T50 Torx driver. Remove the universal clutch compressor and stationary sheave. 6. Inspect the sheaves for excessive wear or damage. Replace if necessary. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.31 © Copyright Polaris Industries Inc.
Page 312 2. Apply Loctite® 648 evenly to bushing bore inside moveable sheave. 3. Set bushing in place on sheave. 4. Install Movable Sheave on puller as shown. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.32 © Copyright Polaris Industries Inc.
Page 313 5. Remove the nut from the puller rod and set aside. 6. Remove the bushing and bushing removal tool from the puller. Discard the bushing. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.33 © Copyright Polaris Industries Inc.
Page 314 6. Once back together, verify the alignment marks made during disassembly are properly aligned. 7. Install the stationary and movable sheave on the vehicle. See PVT Inner Cover Assembly, page 5.13 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.34 © Copyright Polaris Industries Inc.
Page 315: Troubleshooting
Drive belt turns over -Abuse (continued throttle -Caution operator to operate machine Belt burnt, thin spots application when vehicle is within guidelines. stationary, excess load) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.35 © Copyright Polaris Industries Inc.
Page 316 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.36 © Copyright Polaris Industries Inc.
Page 317 Verify EBS spring is in the proper position. Clunking noise on drive away Normal operation No action needed 9928487 R01 - 2018 RANGER XP 1000 Service Manual 5.37 © Copyright Polaris Industries Inc.
Page 318 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 322 Snorkel Tube Tool 2871699 Rear Driveshaft Seal Guide Rear Output Seal Driver 2871698 Bearing Seal Driver (50 mm) 2871282 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 323 26 ft-lbs (35 Nm) 14 ft-lbs (19 Nm) Bellcrank Nut Sector Cover Fastener (QTY 5) 10 ft-lbs (14 Nm) Park Plate Fastener (QTY 3) 9 ft-lbs (12 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 324 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 325 7. Perform the previous steps in reverse order to reinstall the shift lever (lever, cable, dash panel, shift knob). 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 326 6. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut against the mount. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 327 This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 328 Planet Gear Assembly 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 329 6. Remove drive and driven clutch and inner clutch cover. Refer to PVT Inner Cover Disassembly, page 5.12 procedure. 7. Remove the vent line from the transmission fitting 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 330 15. Place a piece of 1x4 wood under the engine to support it. Remove the rear transmission isolator fasteners 12. Remove lower manifold mounting fastener to transmission mount bracket. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.10 © Copyright Polaris Industries Inc.
Page 331 TRANSMISSION 16. Remove the two fasteners retaining the rear isolator to the frame bracket. 17. Lift the transmission out the top of the vehicle chassis. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.11 © Copyright Polaris Industries Inc.
Page 332 3. Install transmission isolator bolt through the transmission bracket and isolator. Torque fasteners to specification. TORQUE Rear Transmission Mount Bracket Fastener: 40 ft-lbs (54 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.12 © Copyright Polaris Industries Inc.
Page 333 8. Install PVT hoses and outer PVT cover. Torque fasteners to specification. TORQUE Hose Clamps: 35 in-lbs (4 Nm) Outer PVT Cover Fasteners: 35 in-lbs (4 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.13 © Copyright Polaris Industries Inc.
Page 334 TORQUE Battery Fasteners: 40 in-lbs (5 Nm) 14. Connect the transmission shift cable to the bellcrank. Install the clip and sliding the washer. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.14 © Copyright Polaris Industries Inc.
Page 335 CAUTION Do not pry on the transmission case mating surfaces or the transmission cases will be damaged and leak oil after it is reassembled. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.15 © Copyright Polaris Industries Inc.
Page 337 Snap Ring Snorkel Tube Thrust Washer Bearing Bearing Snap Ring Ring Gear Thrust Washer Front Output Shaft Snap Ring O-Ring Seal 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.17 © Copyright Polaris Industries Inc.
Page 338 CAUTION Support the end face of the gear teeth when pushing the shaft through or damage to the gear teeth may occur. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.18 © Copyright Polaris Industries Inc.
Page 339 If bushing replacement is required, proceed to Planetary Differential Bushing Replacement, page 6.20. 2. Remove the six screws retaining the differential cover and remove the cover. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.19 © Copyright Polaris Industries Inc.
Page 340 3. Press the new bushing into the ring gear housing. 4. Install the bushing flush to 1mm past the end of the ring gear hub as shown. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.20 © Copyright Polaris Industries Inc.
Page 341 4. Install the bushing flush to 1mm past the end of the for any unwanted burs. differential cover as shown. 3. Press the new bushing into the side gear until it bottoms out. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.21 © Copyright Polaris Industries Inc.
Page 342 4. Apply Loctite® 2760 to cover screws. TORQUE Differential Cover Screws (8.8 Fastener): 20 ft-lbs (27 Nm) TORQUE Differential Cover Screws (10.9 Fastener): 28 ft-lbs (38 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.22 © Copyright Polaris Industries Inc.
Page 343 Inspect all of the gears, shafts, and bearings shown for excessive wear or damage. IMPORTANT If gear replacement is required, also replace the corresponding gear and/or gear shaft. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.23 © Copyright Polaris Industries Inc.
Page 344 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.24 © Copyright Polaris Industries Inc.
Page 345 If you have a hard time seeing into the hole, insert a shaft bevel gear. small Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.25 © Copyright Polaris Industries Inc.
Page 346 Snorkel Locking Screw: 9 ft-lbs (12 Nm) TORQUE Shift Fork Screws: 17 lb-ft (23 Nm) 3. Slide engagement dog onto retaining pins of shift fork. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.26 © Copyright Polaris Industries Inc.
Page 347 Both shift forks need to be orientated the same way, so that the shift fork pins are both offset to the same side of the rail. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.27 © Copyright Polaris Industries Inc.
Page 348 Inspect the splines of the shift drum. freely. Twist the cam away from it’s free state position and make sure it snaps back into it’s free state. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.28 © Copyright Polaris Industries Inc.
Page 349 13. Install the transmission case cover and retaining bolts . Torque bolts to specification. IMPORTANT Make sure the transmission is in HIGH gear prior to reassembly 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.29 © Copyright Polaris Industries Inc.
Page 350 Install the nut and torque to specification. 25. Refer to Transmission Installation, page 6.12 to complete the repair. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.30 © Copyright Polaris Industries Inc.
Page 351 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 6.31 © Copyright Polaris Industries Inc.
Page 355 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 356 The vent line ends its routing secured into a horizontal section of the frame with a vent line termination fitting. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 357 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 358 Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. 5. Inspect bearing carrier housing for scratches, wear or damage. Replace front bearing carrier if damaged. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 359 TORQUE Front Caliper Mounting Bolts: TORQUE 30 lb-ft (41 Nm) Tie Rod End Fastener: 40 lb-ft (54 Nm) 5. Apply grease to the drive shaft splines. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 360 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 361 3. Install drive shaft into the front bearing carrier. 4. Install the front bearing carrier. Refer to BEARING CARRIER INSTALLATION procedure earlier this chapter. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 362 2. Remove Driver Seat. • Lift up on Release Lever 1. Flip up passenger seat. • Tilt seat forward. • Slide seat rearward to remove. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.10 © Copyright Polaris Industries Inc.
Page 363 7. Remove eight push rivets and remove center console. 5. Remove Battery Bracket Fastener and Bracket Remove Battery. 8. Remove two push rivets from hard intake. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.11 © Copyright Polaris Industries Inc.
Page 364 11. Slide the plastic intake rearward & then frontward to angle out driverside of vehicle. 12. Remove two carrier bolts 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.12 © Copyright Polaris Industries Inc.
Page 365 NOTE Use a small pic to help aid in getting the rubber lines to engage of all sides of the plastic intake. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.13 © Copyright Polaris Industries Inc.
Page 366 13. Install battery cover. TORQUE Battery Box Fasteners: 3.5 ft-lbs (5 Nm) 11. Install Battery. Install Battery Bracket and Battery Bracket Fastener Torque Fastener specification. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.14 © Copyright Polaris Industries Inc.
Page 367 FINAL DRIVE 14. Install Driver Seat. • Engage front seat base tabs. • Push seat down until properly seated. 15. Fold down passenger seat. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.15 © Copyright Polaris Industries Inc.
Page 368 Access the Rear Prop Shaft from the rear driver side of the vehicle. TORQUE Rear Prop Shaft Fasteners: 40 ft-lbs (54 Nm) 3. Perform Front Prop Shaft Installation, page 7.13. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.16 © Copyright Polaris Industries Inc.
Page 369 5. Tighten clamp with hand tools to force U-joint cups out of yoke. 6. Discard and replace all U-joint parts that were removed from the yoke. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.17 © Copyright Polaris Industries Inc.
Page 370 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.18 © Copyright Polaris Industries Inc.
Page 371 11. Tighten clamp until other cap is below retaining ring groove. 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.19 © Copyright Polaris Industries Inc.
Page 372 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.20 © Copyright Polaris Industries Inc.
Page 373 . The front drive will remain engaged until the torque requirement goes away (i.e. rear wheels regain traction). 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.21 © Copyright Polaris Industries Inc.
Page 374 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.22 © Copyright Polaris Industries Inc.
Page 375 7. Remove the vent hose from the front gearcase. 8. Remove the front gearcase from the left-hand side between the upper and lower control arms. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.23 © Copyright Polaris Industries Inc.
Page 376 . Refer to AWD DIAGNOSIS for detailed inspection process. 6. Remove the clutch housing / ring gear and roll cage assembly from the gearcase housing. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.24 © Copyright Polaris Industries Inc.
Page 377 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.25 © Copyright Polaris Industries Inc.
Page 378 Bearing Roller Surface Spacer Thrust Bearing 16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.26 © Copyright Polaris Industries Inc.
Page 379 6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.27 © Copyright Polaris Industries Inc.
Page 380 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: 9 ft-lbs (12 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.28 © Copyright Polaris Industries Inc.
Page 381 5. Drive a new roll pin into the front propshaft yoke. 6. Install the front drive shafts into the front gearcase. Refer to FRONT DRIVE SHAFT INSTALLATION procedure. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.29 © Copyright Polaris Industries Inc.
Page 382 Also, if the outer wheel slips or loses traction the inner wheel will then begin to slow the vehicle as well. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.30 © Copyright Polaris Industries Inc.
Page 383 “AWD Diagnosis” for detailed inspection process. NOTE Press on the output hub assembly while lifting up on the outer cover plate to prevent removing more than the cover plate. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.31 © Copyright Polaris Industries Inc.
Page 384 Inspect the roll cage for damage or cracks. The rollers must slide up and down freely within the roller cage surfaces. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.32 © Copyright Polaris Industries Inc.
Page 385 Inspect the input shaft bearing for signs of wear. Replace the input shaft cover O-ring prior to reassembly. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.33 © Copyright Polaris Industries Inc.
Page 386 4. Install input shaft, bearing, and snap ring 20. Thoroughly clean the gearcase components before beginning reassembly. 5. Press the pinion shaft seal into the gearcase, until the seal is flush. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.34 © Copyright Polaris Industries Inc.
Page 387 NOTE Verify armature plate tabs are in the slots on the roll cage and are resting in the ring gear grooves. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.35 © Copyright Polaris Industries Inc.
Page 388 Verify the square O-ring is placed flat on the cover surface. If the O-ring is twisted, fluid leaks may occur. 15. Torque the cover plate bolts to specification. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.36 © Copyright Polaris Industries Inc.
Page 389 If it locks vehicle. to the drive train in only one direction, ADC is not indexing cage in both directions 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.37 © Copyright Polaris Industries Inc.
Page 390 If pole faces are severely problem has been fixed. If worn and damaged, not, continue onto replace output cover. additional problems listed. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.38 © Copyright Polaris Industries Inc.
Page 391 Step 4. A band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.39 © Copyright Polaris Industries Inc.
Page 392 7. Remove the upper and lower A-arm fasteners from the bearing carrier. 8. Remove the bearing carrier. Inspect the bearing again for smoothness and side to side movement, replace as needed. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.40 © Copyright Polaris Industries Inc.
Page 393 Use care to not allow any of the Loctite ® compound to get in the bearing. 8. Wipe the housing clean of any excess compound and install the snap ring. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.41 © Copyright Polaris Industries Inc.
Page 395 6. Remove the upper A-arm fastener. 10. Refer to the “DRIVE SHAFT SERVICE”, page 7.45 section if repairing the drive shaft. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.43 © Copyright Polaris Industries Inc.
Page 398 3. Clean the grease from the face of the joint. 4. Place the drive shaft in a soft-jawed vise. 7. Remove the CV boot from the shaft. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.46 © Copyright Polaris Industries Inc.
Page 400 3. Clean the grease from the face of the joint. 4. Place the drive shaft in a soft-jawed vise. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.48 © Copyright Polaris Industries Inc.
Page 401 7. Remove the boot from the shaft. inner race. Pack the ball tracks and outer face flush with grease. Place any remaining grease into the boot. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.49 © Copyright Polaris Industries Inc.
Page 402 Make sure the boot is not dimpled or collapsed. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9928487 R01 - 2018 RANGER XP 1000 Service Manual 7.50 © Copyright Polaris Industries Inc.
Page 404 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 405 Tie Rod Jam Nut Power Steering Unit Frame 30 ft-lbs (41 Nm) Tie Rod Retaining Nut + 90° Power Steering Unit Frame 14 ft-lbs (19 Nm) Fasteners 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 406 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 407 3. Remove the three fasteners retaining the steering rack to the frame. 4. Remove Steering Rack from vehicle. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 408 Steering Rack Mounting Nuts: TORQUE 40 ft-lbs (54 Nm) Tie Rod Retaining Nut: 30 ft-lbs (41 Nm) + 90° 5. Perform Wheel Toe Adjustment, page 2.55. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 409 10. Reinstall the steering shaft assembly in the vehicle. Install the lower portion of the steering shaft onto the steering gear box assembly. Torque the lower pinch bolt to specification. 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 411 WARNING 7 ft-lbs (10 Nm) Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component 10. Reconnect both electrical harnesses onto the power repair and adjustment be performed by an authorized steering unit. Be sure the connectors snap into place Polaris MSD certified technician.
Page 412 • If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut). 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.10 © Copyright Polaris Industries Inc.
Page 413 Damage may not be immediately apparent if done incorrectly. • After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 13 ft-lbs (18 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.11 © Copyright Polaris Industries Inc.
Page 414 Front Ball Joint Nut: 45 ft-lbs (61 Nm) WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.12 © Copyright Polaris Industries Inc.
Page 415 , Bushings , and Pivot Shaft into new A-arm. A light press force may be needed.. CAUTION Do not damage brake line during this process 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.13 © Copyright Polaris Industries Inc.
Page 416 9. Install new ball joint into A-arm. Refer to “Ball Joint Service” section. 10. Insert new A-arm bushings and pivot tube into new A- arm. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.14 © Copyright Polaris Industries Inc.
Page 417 (PU-50506) on the upper ball joint. To service the lower ball joint: 6. Remove and discard the lower ball joint pinch bolt. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.15 © Copyright Polaris Industries Inc.
Page 418 A-arm to engage the ball joint Removal Adapter. NOTE Be sure the Press Asm. opening is only contacting the Spacer and not the ball joint face. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.16 © Copyright Polaris Industries Inc.
Page 419 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) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.17 © Copyright Polaris Industries Inc.
Page 420 A-arm to the frame. 9. Allow the lower A-arm to drop and remove the upper A-arm by maneuvering the rear shock and stabilizer link out. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.18 © Copyright Polaris Industries Inc.
Page 421 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.19 © Copyright Polaris Industries Inc.
Page 422 A-arm. 6. Remove the fastener retaining the lower A-arm to the bearing carrier and frame. 7. Remove the lower A-arm from the vehicle. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.20 © Copyright Polaris Industries Inc.
Page 423 31 ft-lbs (42 Nm) WARNING Stabilizer Bar Link Fasteners: 17 ft-lbs (23 Nm) Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.21 © Copyright Polaris Industries Inc.
Page 424 5. Turn adjustment cam to set preload distance noted in Step 1. 6. Reinstall shock onto vehicle and torque new fasteners to specification. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 8.22 © Copyright Polaris Industries Inc.
Page 427 MAX LEVEL line! maximum pad service life. When servicing Polaris brake systems use only Polaris • DO NOT over-fill the master cylinder fluid reservoir. DOT 4 Brake Fluid (PN 2872189). • Make sure the brake pedal returns freely and completely.
Page 428 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) 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 429 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 431 BRAKE SYSTEM REAR BRAKE LINE FROM MASTER CYLINDER TO JUNCTION BLOCK REAR BRAKE LINES FROM JUNCTION BLOCK TO REAR CALIPERS 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 432 BRAKE SYSTEM BRAKE LINE CLOCKING ITEM DESCRIPTION To Tee Block To Right Front Caliper To Left Front Caliper 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc.
Page 433 When bleeding the brakes or replacing the fluid always start with the furthest caliper from the master cylinder. This procedure should be used to change fluid or bleed brakes during regular maintenance. Polaris DOT 4 Brake Fluid P/N: 2872189 CAUTION 5. Begin bleeding procedure with caliper furthest from Always wear safety glasses.
Page 434 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.10 © Copyright Polaris Industries Inc.
Page 435 CAUTION Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.11 © Copyright Polaris Industries Inc.
Page 436 6. Follow the Brake Fluid Replacement / Brake Bleeding, page 9.9 procedure. 7. Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.12 © Copyright Polaris Industries Inc.
Page 437 2. Install brake pedal to the pedal mount bracket and secure with pin and clip. 3. Install the clevis pin and retaining clip securing the brake pedal to the master cylinder arm. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.13 © Copyright Polaris Industries Inc.
Page 438 6. Remove the inner pad from the bracket and caliper. NOTE When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.14 © Copyright Polaris Industries Inc.
Page 439 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.15 © Copyright Polaris Industries Inc.
Page 440 Master Cylinder Fluid Up to MAX line inside reservoir 7. Install wheel and torque wheel nuts to specification. TORQUE Wheel Lug Nuts: 120 ft-lbs (163 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.16 © Copyright Polaris Industries Inc.
Page 441 PART DESCRIPTION PART DESCRIPTION Brake Pad Assembly Brake Piston Caliper Mount Assembly Ring Bolt Brake Caliper Pin Seal Boot Bleeder Screw Pin Bushing Boot Plug Cap 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.17 © Copyright Polaris Industries Inc.
Page 442 Remove brake line from caliper. 5. Loosen brake pad adjustment set screw to allow brake pad removal after the caliper is removed. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.18 © Copyright Polaris Industries Inc.
Page 443 Be sure to clean the seal grooves in caliper body. NOTE Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.19 © Copyright Polaris Industries Inc.
Page 444 Replace if damaged or worn beyond drag upon assembly. service limit. 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. MEASUREMENT Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore Front Caliper Piston Bore I.D.:...
Page 445 NOTE If new brake pads are installed, brake burnishing is recommended. TORQUE Brake Line Banjo Bolts: 15 ft-lbs (20 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.21 © Copyright Polaris Industries Inc.
Page 446 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.22 © Copyright Polaris Industries Inc.
Page 447 Brake Disc Mounting Bolts: 18 ft-lbs (24 Nm) 5. Install wheel hub assembly, washers, and castle nut. Torque castle nut to specification and install a new cotter pin. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.23 © Copyright Polaris Industries Inc.
Page 448 4. Remove caliper mounting bolts and lift caliper off of disc. NOTE When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.24 © Copyright Polaris Industries Inc.
Page 449 5. 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 master cylinder. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.25 © Copyright Polaris Industries Inc.
Page 451 PART DESCRIPTION PART DESCRIPTION Brake Pad Assembly Brake Piston Caliper Mount Assembly Ring Bolt Brake Caliper Pin Seal Boot Bleeder Screw Pin Bushing Boot Plug Cap 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.27 © Copyright Polaris Industries Inc.
Page 452 5. If necessary, loosen brake pad adjustment set screw 2-3 turns to allow brake pad removal after the caliper is removed. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.28 © Copyright Polaris Industries Inc.
Page 453 & 4. Using a hammer and a small punch, remove the piston from the caliper body . Remove the square O-rings from the caliper body 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.29 © Copyright Polaris Industries Inc.
Page 454 Replace if damage is evident or if worn beyond may drag upon assembly. service limit. 2. Coat piston with clean Polaris DOT 4 Brake Fluid. MEASUREMENT Install piston with a twisting motion while pushing inward.
Page 455 4. Follow the BRAKE BLEEDING / FLUID CHANGE procedure as outlined earlier in this chapter. 5. Install wheel and torque wheel nuts to specification. TORQUE Wheel Lug Nuts: 120 ft-lbs (163 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.31 © Copyright Polaris Industries Inc.
Page 456 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.32 © Copyright Polaris Industries Inc.
Page 457 Rear Brake Disc Mounting Bolts: 28 lb-ft (38 Nm) 5. Install wheel hub assembly, washers, and castle nut. Torque castle nut to specification and install a new cotter pin. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.33 © Copyright Polaris Industries Inc.
Page 458 • Caliper pistons sticking • Improper assembly of brake system components PEDAL VIBRATION • Disc damaged • Disc worn (runout or thickness variance exceeds service limit) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 9.34 © Copyright Polaris Industries Inc.
Page 461 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.3 © Copyright Polaris Industries Inc.
Page 462 PLATE, SKID 6 ft-lbs (8 Nm) SKID PLATE FASTENERS 10 ft-lbs (14 Nm) SEAT BASE FASTENERS 14 ft-lbs (19 Nm) CROSS BAR FASTENERS WASHER, SKID PLATE 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.4 © Copyright Polaris Industries Inc.
Page 463 COVER, UPPER GLOVEBOX UPPER GLOVEBOX FASTENER 10 in-lbs (1 Nm) UPPER GLOVEBOX BIN DASH-UPPER DASH, STORAGE FASTENER 42 in-lbs (5 Nm) LOWER STORAGE BIN DASH, LOWER STORAGE 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.5 © Copyright Polaris Industries Inc.
Page 464 42 in-lbs (5 Nm) HINGE PIN-GLOVEBOX GLOVEBOX SEAL SEAM GLOVEBOX LATCH 1/4 TURN 36 in lbs (4 Nm) UPPER GLOVEBOX COVER DASH CONTROLS DASH-MAIN FASTENING NUT 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.6 © Copyright Polaris Industries Inc.
Page 465 FENDER, FRONT LH 22 in lbs (3 Nm) FENDER FLARE, LH GROMMET, LATCH WASHER LATCH, 1/4 TURN FRONT FASCIA AND GRILL FASTENERS 42 in-lbs (5 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.7 © Copyright Polaris Industries Inc.
Page 466 DRIVER FLOOR LH FENDER FLARE FLOOR, UPPER CLOSEOFF FLOOR FASTENER 42 in-lbs (5 Nm) PUSH RIVET LINDER, UNDER HOOD RH FENDER FLARE COVER, TUNNEL-FLOOR PASSENGER FLOOR 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.8 © Copyright Polaris Industries Inc.
Page 467 PUSH RIVET LEFT REAR ROCKER PANEL PLUG COMPARTMENT RH BIN STORAGE PUSH RIVET REAR LOWER CLOSE OFF PANEL M6 NUT RIGHT REAR ROCKER PANEL COVER, SEAT-PIVOT 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.9 © Copyright Polaris Industries Inc.
Page 468 40 ft-lbs (54 Nm) SEAT BUCKLE WASHER SEAT BUCKLE FASTENING NUT DRIVER SEAT BACK ASSEMBLY DRIVER SEAT BOTTOM ASSEMBLY DRIVER SEAT BUCKLE PASSENGER SEAT BUCKLE PASSENGER SEAT BOTTOM 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.10 © Copyright Polaris Industries Inc.
Page 469 SEAT SLIDE ASSEMBLY FASTENER 6 ft lbs (8 Nm) SEAT BACK FRAME FASTENER 10 ft lbs (14 Nm) SEAT BACK FRAME SEAT BACK FASTENER 18 inch-lbs (2 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.11 © Copyright Polaris Industries Inc.
Page 470 WELD, CAB FRAME NUT WELD-SEAT, BOLSTER FASTENERS 10 ft-lbs (14 Nm) BOLSTER, BRACKET FASTENERS 6 ft-lbs (8 Nm) RIVET PLATE, WINDSHIELD MOUNT FASTENERS 36 ft-lbs (49 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.12 © Copyright Polaris Industries Inc.
Page 471 DOOR ASSEMBLY-RH DOOR RETAINER SPAER WASHER STRIKER HARDWARE 17 lb-ft (23 Nm) DOOR RETAINER FASTENER 6 lb-ft (8 Nm) DOOR RETAINER NUT 6 lb-ft (8 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.13 © Copyright Polaris Industries Inc.
Page 472 ROOF ASSEMBLY VIEW DESCRIPTION TORQUE CLIP DART HEADLINER WASHER HEADLINER FASTENER 24 in-lbs (3 Nm) OVERHEAD LIGHT FASTENER 18 in lbs (2 Nm) OVERHEAD LIGHT PUSH RIVET 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.14 © Copyright Polaris Industries Inc.
Page 473 BODY / FRAME DESCRIPTION TORQUE ROOF ASSEMBLY ROOD SIDE SEAL ROOF FASTENER REAR ROOF SEAL ROOF FASTENER 42 in-lbs (5 Nm) ROOF FASTENER CLIP FRONT ROOF SEAL 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.15 © Copyright Polaris Industries Inc.
Page 474 12 ft-lbs (16 Nm) EVAPORATOR HEATER RETURN HOSE HEATER SUPPLY HOSE AC SUCTION HOSE HVAC MOUNTING WASHER HVAC MOUNTING FASTENER 8 ft-lbs (11 Nm) MAIN HVAC ASSEMBLY 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.16 © Copyright Polaris Industries Inc.
Page 475 FILTER SUPPORT FASTENER 18 in-lbs (2 Nm) AIR FILTER AIR FILTER BAND CLAMP 24 in-lbs (3 Nm) CENTER DASH DUCTING ASSEMBLY DEFROST VENT DUCTING ASSEMBLY, LH 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.17 © Copyright Polaris Industries Inc.
Page 476 Torque until lock and ride clamps are fully seated REAR GLASS FASTENER NUT Torque until lock and ride clamps are fully seated WASHER WASHER WASHER 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.18 © Copyright Polaris Industries Inc.
Page 477 42 in-lbs (5 Nm) TAILGATE OUTER PANEL OUTER TAILGATE PANEL FASTENER 22 in lbs (2 Nm) TAILGATE OUTER PANEL TAILGATE CABLE TAILGATE ROD CLIP TAILGATE LATCH SPRING 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.19 © Copyright Polaris Industries Inc.
Page 478 TAILGATE SUPPORT FASTENER M6x1.0 42 in-lbs (5 Nm) TAILGATE LATCH FASTENER 7 ft lbs (9 Nm) TAILGATE LATCH TAILGATE SUPPORT FASTENER M6x1.0 42 in-lbs (5 Nm) TAILGATE BUMPER 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.20 © Copyright Polaris Industries Inc.
Page 479 5 ft lbs (7 Nm) CARGO BOX FRAME FASTENING NUT 5 ft lbs (7 Nm) CARGO BOX SUPPORT FRAME CARGO BOX LATCH HANDLE BOX BUMPER CARGO BOX HEAT SHIELD 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.21 © Copyright Polaris Industries Inc.
Page 480 Ensure proper door alignment. overhead light to the headliner. Remove the headliner. 3. Remove the fasteners holding the roof to the frame. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.22 © Copyright Polaris Industries Inc.
Page 481 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 482 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.24 © Copyright Polaris Industries Inc.
Page 483 3. Carefully pull the bumper straight out to remove it from the vehicle. TORQUE Front Bumper Fasteners 30 ft-lbs (41 Nm) 4. Slide seat rearward to remove. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.25 © Copyright Polaris Industries Inc.
Page 484 2. Install the two push rivets behind the front fascia. 3. Remove the two push rivets behind the front fascia. 4. Pull upper fender straight out as shown. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.26 © Copyright Polaris Industries Inc.
Page 485 4. Install the hood by inserting into slots and locking down with 1/4 turn fasteners. 4. Pull the lower fender straight out from vehicle to remove. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.27 © Copyright Polaris Industries Inc.
Page 486 1. Install the lower fender straight on as shown. 4. Reinstall the upper fender. 2. Install the five T-40 torx fasteners and torque to specification. TORQUE Body Fastener 42 in-lbs (5 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.28 © Copyright Polaris Industries Inc.
Page 487 . Repeat procedure on passenger side. 4. Pull the front fascia straight up to remove as shown. NOTE Front Bumper removed for clarity. 2. Remove the two T-40 torx fasteners 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.29 © Copyright Polaris Industries Inc.
Page 488 2. Reinstall the headlight assembly. Install the three T- 25 torx fasteners . Do not tighten. Connect the headlight connector. 3. Install the two T-40 torx fasteners . Torque to specification. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.30 © Copyright Polaris Industries Inc.
Page 489 2. Un-clip the two retaining tabs from the instrument cluster panel. 5. Perform Headlight Adjustment. SeeHeadlight Adjust- ment, page 11.21 6. Reinstall upper fender. SeeFront Fender Service, page 10.26 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.31 © Copyright Polaris Industries Inc.
Page 490 12 in lbs (1 Nm) 4. Remove the two push rivets on the upper center storage cover and unlock the two retaining tabs 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.32 © Copyright Polaris Industries Inc.
Page 491 Low or High gear to ease removal. 9. Carefully pull the lower dash panel towards the seat and up to remove it. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.33 © Copyright Polaris Industries Inc.
Page 492 42 in-lbs (5 Nm) 2. Remove the two push rivets on the back side of the rear upper fender. Lift up and remove the upper fender. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.34 © Copyright Polaris Industries Inc.
Page 493 5. Remove the push rivets retaining the center console, and remove the cover from the vehicle. 8. Remove the T-40 torx fasteners and the push rivets 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.35 © Copyright Polaris Industries Inc.
Page 494 3. Install the passenger floor. Install the push rivets and the T-40 torx fasteners. Torque to specification. TORQUE Body Fasteners: 42 in-lbs (5 Nm) TORQUE Body Fasteners: 42 in-lbs (5 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.36 © Copyright Polaris Industries Inc.
Page 495 • Refer to accessory kit instructions for accessory removal and installation. TORQUE Body Fasteners: 42 in-lbs (5 Nm) 5. Install the center console. Install the push rivets retaining the center console. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 10.37 © Copyright Polaris Industries Inc.
Page 500 • For resistance readings, isolate the component to be • ECU* tested. Disconnect it from the wiring harness or power • Speed Key Accessory (if installed) supply. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.4 © Copyright Polaris Industries Inc.
Page 501 Stator Leg Voltage (3000 47 VAC ± 25% RPM) Stator Leg Voltage (5000 79 VAC ± 25% RPM) Starter Solenoid Terminal 2.5 Ω ± 20% Resistance (77 °F) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.5 © Copyright Polaris Industries Inc.
Page 502 See Brake Fluid Replacement / Brake Bleeding, page 9.9. NOTE Pins 9 and 10 provide power and ground to light the switch lamp. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.6 © Copyright Polaris Industries Inc.
Page 503 • Move the switch to TURF. There should be continuity between switch pins 1 and 2; 5 and 6. NOTE Pins 2 and 9 provide power and ground to light the switch lamp. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.7 © Copyright Polaris Industries Inc.
Page 504 2. Test for continuity between the EFI Relay and the switch. 3. Test for continuity between the switch and the ECU pin. 4. Test for continuity across the switch. Seat Belt Switch: Normally Open 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.8 © Copyright Polaris Industries Inc.
Page 505 3. If the resistance is out of specification for any mode, replace the switch. Drive Mode Switch Performance: 4750 Ω Standard: 25,000 Ω Work: 1600 Ω 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.9 © Copyright Polaris Industries Inc.
Page 506 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.10 © Copyright Polaris Industries Inc.
Page 507 • Remove solenoid from rear differential and ensure the solenoid plunger is actuating. CAUTION Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.11 © Copyright Polaris Industries Inc.
Page 508 3. To install, reverse the removal procedure. Torque the solenoid fastener to specification. TORQUE Differential Solenoid Nut: 25 lb-ft (34 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.12 © Copyright Polaris Industries Inc.
Page 509 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.13 © Copyright Polaris Industries Inc.
Page 510 This lamp illuminates when fuel level in the fuel tank is low. Speed Key Information about the speed key is provided in (optional the accessory kit. accessory) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.14 © Copyright Polaris Industries Inc.
Page 511 A flashing wrench symbol alerts the operator reached. To reset, see Indicator that the preset service interval has been reached. Your POLARIS dealer can provide Programmable Service scheduled maintenance. See Programmable Interval, page 11.17. Service Interval, page 11.17 for resetting instructions.
Page 513 1. Press either toggle button to cycle to the trip time option (TT). 2. Press and hold either toggle button until the meter resets to zero. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.17 © Copyright Polaris Industries Inc.
Page 514 EPS fault code, the EPS lamp will blink. 4. Record the three (3) numbers displayed. 5. Press MODE to exit to the settings menu. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.18 © Copyright Polaris Industries Inc.
Page 517 Due to the nature of light utility vehicles and where they are operated, headlight lenses become dirty. Frequently washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.21 © Copyright Polaris Industries Inc.
Page 519 Make sure the tab on the bulb locates properly in the housing. 6. Install the harness onto the new headlight bulb and install the hood. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.23 © Copyright Polaris Industries Inc.
Page 520 4. Install the new LED lamp assembly by reversing this procedure. 5. Test the tail light / brake light after installation to verify proper function. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.24 © Copyright Polaris Industries Inc.
Page 522 1.22 kΩ ± 2% NOTE If the coolant temperature sensor or circuit malfunctions the radiator fan will default to 'ON' while the engine is running. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.26 © Copyright Polaris Industries Inc.
Page 523 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.27 © Copyright Polaris Industries Inc.
Page 524 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 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.28 © Copyright Polaris Industries Inc.
Page 525 Coil High Power In AC Switch Relay Power In Power Out Start Relay Power Out Coil Low Coil Low Coil High HVAC Power Relay Power In 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.29 © Copyright Polaris Industries Inc.
Page 527 Red / Dark Blue system circuits. 12 Vdc power input from key Orange switch to enable relay. Provides 12 Vdc power for EPS Orange operation. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.31 © Copyright Polaris Industries Inc.
Page 528 Blue Solenoid. NOTE The Rear Diff Solenoid Relay is mounted separately, attached to the rear portion of the main frame under the rear cargo box. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.32 © Copyright Polaris Industries Inc.
Page 529 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 530 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.34 © Copyright Polaris Industries Inc.
Page 531 4. Cut the compressor drive belt to remove it from the vehicle. INSTALLATION 1. Install new alternator. Do not torque fasteners. 2. Connect alternator electrical connection. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.35 © Copyright Polaris Industries Inc.
Page 532 Alternator Cover Fasteners: 48 lb-in (5.4 Nm) 11. Install the outer alternator cover and torque the fasteners to specification. TORQUE Alternator Cover Fasteners: 48 lb-in (5.4 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.36 © Copyright Polaris Industries Inc.
Page 533 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.37 © Copyright Polaris Industries Inc.
Page 534 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: 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.38 © Copyright Polaris Industries Inc.
Page 535 • All associated circuits have no shorts to ground. Testing For A Short To Ground, page 11.42 Polaris advises to only use a high quality DMM that • All associated circuits have no shorts to voltage. meets the same standards as the Fluke™ 77 (PV-43568) Testing For A Short To Voltage, page 11.43...
Page 536 To avoid causing damage, use of the appropriate adapters is required. Most terminals used on Polaris NOTE machines can be tested using terminal test kit PV–...
Page 537 Testing For A Short To Voltage, page 11.43 For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.41 © Copyright Polaris Industries Inc.
Page 538 Testing For A Short To Voltage, page 11.43 For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.42 © Copyright Polaris Industries Inc.
Page 540 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.44 © Copyright Polaris Industries Inc.
Page 542: Battery Service
2. Test battery with a voltage meter or load tester to determine battery condition. This will determine the length of time required to charge the battery to full capacity. 3. Charge the battery as recommended. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.46 © Copyright Polaris Industries Inc.
Page 543 NOTE Battery charge can be maintained by using a Polaris A battery may indicate a full charge condition in the OCV battery tender charger or by charging once a month to test, but still may not have the storage capacity make up for normal self-discharge.
Page 544 NOTE Authorized Polaris dealers/distributors are required to Charge the battery using an automatic charger that will use the conductance analyzer when testing 12V Polaris not exceed 14.6 Vdc. An automatic charger will signal batteries. when charging is complete.
Page 545 Voltage should not exceed .1 DC volts per connection NOTE The negative (-) battery cable is mounted to the engine using the upper starter mounting bolt / stud. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.49 © Copyright Polaris Industries Inc.
Page 546 (bendix) with the flywheel. This helps prevent binding and starter damage. TORQUE Starter Motor Fasteners: 7 lb-ft (10 Nm) 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.50 © Copyright Polaris Industries Inc.
Page 547 • 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. 9928487 R01 - 2018 RANGER XP 1000 Service Manual 11.51 © Copyright Polaris Industries Inc.
Page 549 NOTE 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 555 Assembly View ............9.17 Fluid Replacement / Brake Bleeding ..... 2.57, 9.9 Disassembly ............9.19 Break-In Period............2.5 Inspection.............9.20 Bushing Replacement Installation ............9.21 A-Arm ............8.13, 8.19 9928487 R01 - 2018 RANGER XP 1000 Service Manual IX.1 © Copyright Polaris Industries Inc.
Page 556 Main Bearing Selection..........3.58 Shift Weight Inspection ..........5.22 Removal / Inspection..........3.47 Spider Removal .............5.21 Crankshaft Position Sensor (CPS) Driven Clutch CPS Replacement ..........4.32 Alignment .............. 5.9 9928487 R01 - 2018 RANGER XP 1000 Service Manual IX.2 © Copyright Polaris Industries Inc.
Page 557 Cylinder Inspection ..........3.50 Bypass Test ............11.26 Cylinder Removal ...........3.51 Operation / Testing ..........11.26 Flywheel Installation ..........3.72 Final Drive Flywheel Removal ..........3.42 AWD Diagnosis............7.22 9928487 R01 - 2018 RANGER XP 1000 Service Manual IX.3 © Copyright Polaris Industries Inc.
Page 558 AWD Operation............7.21 Overview ............3.121 Replacement............3.121 Disassembly / Inspection .........7.23 Hood Disassembly / Inspection (ADC) ........7.31 Installation ............7.29 Assembly View ............10.7 Operation (ADC) ............7.30 HVAC 9928487 R01 - 2018 RANGER XP 1000 Service Manual IX.4 © Copyright Polaris Industries Inc.
Page 559 Ring Installation .............3.59 Pre-Ride..............2.6 Instrument Cluster Ring Installed Gap ..........3.54 Overview ............11.13 Piston to Cylinder Clearance........3.54 Polaris Mobile Digital Wrench (PMDW) ......4.56 Pinouts .............. 11.18 Intake Manifold Power Steering Unit (EPS) Installation ............3.17 Installation ............. 8.8 Pre-Ride / Daily Inspection ..........2.32 Removal...............3.15...
Page 560 Lower Seat Base Removal ........10.25 Starter Solenoid Sensor Bench Test............11.50 Oxygen ..............4.40 Operation ............11.51 Speed..............11.10 Starting System Service ..............11.39 Starter Motor Installation ........11.50 9928487 R01 - 2018 RANGER XP 1000 Service Manual IX.6 © Copyright Polaris Industries Inc.
Page 561 Ignition..............11.7 EPS Non-Functional MIL Off ........11.56 EPS Non-Functional MIL On ........11.55 Seat Belt Interlock ..........11.8 Switches EPS Using Digital Wrench®........11.57 9928487 R01 - 2018 RANGER XP 1000 Service Manual IX.7 © Copyright Polaris Industries Inc.
Page 562 VIN Number .............1.18 Voltage Drop ............11.45 Voltage Drop Test ............ 11.49 Water Pump Housing Removal ...........3.41 Installation ............3.94 Removal...............3.93 Service ..............3.95 Wiring Diagrams Chassis..............59 9928487 R01 - 2018 RANGER XP 1000 Service Manual IX.8 © Copyright Polaris Industries Inc.
Page 563 Chassis Schematic - BASE INSTRUMENT CLUSTER POWER STEERING ASSEMBLY RECEPTACLE RECEPTACLE FUNCTION FUNCTION CAN HIGH EPS POWER (A) CAN LOW TRAILER TURN SIGNAL (B+) DRIVE MODE SWITCH WINCH DASH WINCH CONTACTOR SEAT BELT SWITCH BOX LIFT HARNESS BOX LIFT ACTUATOR FUNCTION SWITCHED POWER (+) FUEL LEVEL INPUT...
Page 564 REVERSE BEEPER Chassis Schematic - HVAC RECEPTACLE RECEPTACLE POWER STEERING ASSEMBLY INSTRUMENT CLUSTER DRIVE MODE SWITCH EPS POWER (A) FUNCTION FUNCTION HPCO Switch FUNCTION CAN HIGH HEADLIGHT SWITCH CAN LOW TRAILER TURN SIGNAL (B+) BATTERY (+) SWITCHED POWER (+) FUEL LEVEL INPUT TRANSMISSION SW BATTERY (-) DIAGNOSTIC...
Page 565 Cargo Box Schematic 2018 - Ranger XP1000 E = ENGINE GROUND C = CHASSIS GROUND NC = SWITCH NORMALLY CLOSED NO = SWITCH NORMALLY OPEN HARNESS: 2413818-02 FILE NAME: 2413818.RSD WIRE COLOR LEGEND BEIGE (TAN) BLACK LIGHT BLUE DARK BLUE BROWN GRAY LIGHT GREEN...

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