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

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Polaris RANGER 1000 2020

Page 1 Publication Printed November 2020 (PN 9850045 R01) © Copyright 2020 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
Page 2 SAFETY WARNINGS The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.
Page 3 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
Page 4 REVISION INDEX DATE CHANGES 11/06/2020 Initial release...
Page 5 FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video. This feedback form is viewable on a mobile...
Page 7 2020-2021 RANGER 1000 Service Manual Chapter Summary CHAPTER 1 : GENERAL INFORMATION CHAPTER 2 : MAINTENANCE CHAPTER 3 : ENGINE / COOLING / EXHAUST CHAPTER 4 : ENGINE ELECTRICAL CHAPTER 5 : FUEL SYSTEM CHAPTER 6 : PVT SYSTEM CHAPTER 7 : TRANSMISSION CHAPTER 8 : FINAL DRIVE...
Page 9: Table Of Contents
POLARIS MOBILE DIGITAL WRENCH® (PMDW)........
Page 11: 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 12: 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.polaris.com). NOTICE When ordering service parts be sure to use the correct parts manual.
Page 13: Replacement Keys
(i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.) SERIES# PART NUMBER 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 14: 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 15: Special Tools Index
Engine Stand PU-50624 Pliers (2” Bore) Valve Spring PV-1253 or PV- Compressor 4019 Engine Stand Adapter (Mounts PU-50562 Cylinder Holding To The Engine) & Camshaft PU-50563 Timing Plate 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 16 Fuel Pressure PA-48838 Gauge Adapter Piston Pin Puller 2870386 Fuel Pressure PS-48762 Gauge Adapter Roller Pin Tool 2870910 Fuel Pump PU-50326 Service Tool Driven Clutch 2883577 Separator Tool 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 17 Axle Boot PU-48951 Clamp Tool Digital Wrench® PU-47471 SmartLink Kit MultiLink XP PU-52789 Module CV Boot Clamp 8700226 Vehicle Interface Pliers PU-52790 Harness MultiLink XP PU-52791 USB Cable 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 18 Multimeter Static Timing 2871745 Light Harness Hall Effect 2460761 Sensor Probe Harness Battery Conductance PU-50296 Analyzer (MDX- 610P) Connector Test PV-43526 Timing Light 2870630 Relay Bypass PU-49466 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.10 © Copyright Polaris Inc.
Page 19: Master Torque List
40 ft-lbs (54 Nm) (M10) Engine Mount Isolator Nuts 22 ft-lbs (30 Nm) (M8) Exhaust Head Pipe 22 ft-lbs (30 Nm) Mounting Fastener Exhaust Stud w/Spring 21 ft-lbs (28 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.11 © Copyright Polaris Inc.
Page 20 One Way Clutch Retaining 9 ft-lbs (12 Nm) Fastener Rear Engine Mount 45 ft-lbs (61 Nm) Fasteners Rear Engine Mount Fasteners (Preliminary 5 ft-lbs (7 Nm) Torque) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.12 © Copyright Polaris Inc.
Page 21 10 ft-lbs (14 Nm) Fuel Tank Bracket Fastener Fastening Nut: M6 x 1.0 7 in-lbs (1 Nm) PVT Outlet Duct Fastener Shift Weight Fastener 20 in-lb (2 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.13 © Copyright Polaris Inc.
Page 22 10 ft-lbs (14 Nm) 20 ft-lbs (27 Nm) Transmission Case Fastener Transmission Fill / Drain 12 ft-lbs (16 Nm) Plug Transmission to Engine 45 ft-lbs (61 Nm) Mount 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.14 © Copyright Polaris Inc.
Page 23 Tie Rod Jam Nut Step 1: 30 ft-lbs (41 Nm) Tie Rod Retaining Nut Step 2: Tighten additional 90° Upper Steering Shaft Pinch 25 ft-lbs (34 Nm) Fastener 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.15 © Copyright Polaris Inc.
Page 24 6 ft-lbs (8 Nm) Weld, Seat Bolster Fastener 10 ft-lbs (14 Nm) Inner Cargo Box Fastener 8 in lbs (1 Nm) 12 in lbs (1 Nm) Instrument Cluster Fastener 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.16 © Copyright Polaris Inc.
Page 25 Tail Light Fasteners 4 lb-ft (5 Nm) 24 in-lbs (3 Nm) Terminal Block Fasteners 30 in-lbs (3.5 Nm) Terminal Block Cables Throttle Pedal Mounting 8 ft-lbs (11 Nm) Fasteners 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.17 © Copyright Polaris Inc.
Page 26: Vehicle Identification
M=2021 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 engine crankcase...
Page 27: Vehicle Specifications
R21TAA99A1 / A7 R21TAA99B1 / B7 R21TAE99A1 / A7 / A9 / AG / AP / R21TAE99B1 / B7 / B9 / BG / BP / R21TAE99FA / JA 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.19 © Copyright Polaris Inc.
Page 28 Wet Sump Lubrication Oil Requirements PS-4 5W-50 Full Synthetic or PS-4 10W-50 Extreme Duty Full Synthetic Oil Capacity 2.5 Qt. (2.4 L) Coolant Capacity 5.0 Qt (4.75 L) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.20 © Copyright Polaris Inc.
Page 29 10 L.E.D. (3.1W) Ignition System Digital CDI Spark Plug / Gap 0.03 in (0.85 mm) Battery / Amp Hr / CCA Polaris Maintenance Free / 32 AH / 575 CCA DC Outlet Standard 12 Volt DRIVETRAIN RANGER 1000 Transmission Type...
Page 30 Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper Front & Rear Brake Fluid DOT 4 • For clutch settings, refer to Clutch Settings page 6.2 in the PVT Chapter. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.22 © Copyright Polaris Inc.
Page 31: Model Specifications - Crew
R20T6A99A1 R20T6A99B1 R20T6E99A9 / AM / AS R20T6E99B9 / BM / BS RANGER 1000 CREW R21T6A99A1 R21T6A99B1 R21T6E99A9 / AG / AP R21T6E99B9 / BG / BP 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.23 © Copyright Polaris Inc.
Page 32 Wet Sump Lubrication Oil Requirements PS-4 5W-50 Full Synthetic or PS-4 10W-50 Extreme Duty Full Synthetic Oil Capacity 2.5 Qt. (2.4 L) Coolant Capacity 5.0 Qt (4.75 L) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.24 © Copyright Polaris Inc.
Page 33 10 L.E.D. (3.1W) Ignition System Digital CDI Spark Plug / Gap 0.03 in (0.85 mm) Battery / Amp Hr Polaris Maintenance Free / 32 AH / 575 CCA DC Outlet Standard 12 Volt DRIVETRAIN RANGER 1000 CREW Transmission Type Polaris Automatic PVT...
Page 34 16 PSI (110 kPa) Rear Tire Air Pressure 20 PSI (138 kPa) Brake System Foot Actuated 4 Wheel Hydraulic – Dual Bore Caliper Front & Rear Brake Fluid DOT 4 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.26 © Copyright Polaris Inc.
Page 35: General Diagnostics Information Overview
Return the vehicle to the Has concern been repaired Are there any codes present? consumer at this time. after Guided Diagnostic? ↓ ↙ 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.27 © Copyright Polaris Inc.
Page 36: Guided Symptom References
Refer to the Symptom Checklist for various conditions. – If the concern has been verified and all of the information has already been collected, please start an Ask Polaris case at this time. If this information has not yet been gathered, gather this information first.
Page 37: Engine And Drivability Diagnostic Procedures
Functional with MIL ON) page 1.69 • Connect to Digital Wrench®. Check codes and continue with Digital Wrench® Guided diagnosis. • If no codes are present, proceed to step 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.29 © Copyright Polaris Inc.
Page 38 • Check exhaust for blockage. • After checking for air supply and fuel pressure, perform leakdown test. • Refer to Engine Cranks but does Not Start page 1.32 for more information. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.30 © Copyright Polaris Inc.
Page 39 System Troubleshooting page 1.60, or Cylinder Misfire Detection page 1.58. These concerns may also be caused by a mechanical failure. • If the concern can not be diagnosed or repaired using normal diagnostic means, please contact Polaris Technical Service Team. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.31...
Page 40: Engine Cranks But Does Not Start
10. Listen for unusual noises while cranking. • If filled with fuel, vehicle starts, and gauge still is not reading test the fuel sending unit. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.32 © Copyright Polaris Inc.
Page 41 – Bent valve or stuck valve – Valve spring broken or weak – Valve not seating properly (bent or carbon accumulated on sealing surface) – Rocker arm sticking 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.33 © Copyright Polaris Inc.
Page 42: Crank No Start Or Slow Crank
• If voltage drop test fails, continue testing to isolate component that will require replacement (starter / starter solenoid / wiring). Acceptable voltage drop during cranking is 0.1 V per connection. 5. Check Brake Switch operation. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.34 © Copyright Polaris Inc.
Page 43: Over Heating
• Check level and correct as necessary. Check maintenance history to determine if oil need to be changed. 7. Check Cooling Fan operation. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.35 © Copyright Polaris Inc.
Page 44: Warning Lights
Guided Diagnostic for further diagnosis. 5. BRAKE WARNING • Detects brake system failure. • Inspect brake system for leaks, damage, etc. Refer to Brake System chapter for more information. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.36 © Copyright Polaris Inc.
Page 45: Engine Troubleshooting
• Cam worn excessively intake components) • Broken throttle cable • Restricted exhaust system • Incorrect ignition timing • Obstruction in air intake • Low fuel pressure • Throttle Body 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.37 © Copyright Polaris Inc.
Page 46 • Low fuel pressure electrical concern / failed) faulty • Poor fuel quality – Poor connections in ignition system – Ignition timing incorrect – Sheared flywheel key 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.38 © Copyright Polaris Inc.
Page 47: Cooling Troubleshooting
• Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) TEMPERATURE TOO LOW • Thermostat stuck open • Contaminated coolant • Thermostat opening too soon 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.39 © Copyright Polaris Inc.
Page 48: Digital Wrench
GENERAL INFORMATION DIGITAL WRENCH DIGITAL WRENCH® SOFTWARE OVERVIEW The Polaris Digital Wrench® software allows a technician to perform the following tasks: • Analyze real-time engine data • Create customer service account records • Generate / upload service reports • Perform guided diagnostic procedures •...
Page 49: Digital Wrench® Software Installation And Updates
To check if a Digital Wrench® software update is following: available, do the following: 1. Open a web browser and log on to your Polaris dealer 1. Open a web browser and log on to the Polaris dealer website (www.polarisdealers.com).
Page 50: Digital Wrench® Communication Errors
If you experience problems connecting to a vehicle, or ‘Connected’ in the lower left corner of the screen. any other Digital Wrench® software-related problem, visit the Digital Wrench® home page (www.polaris.diagsys. 5. Once connected, proceed with using Digital com) and locate the following information under Wrench®.
Page 51: Digital Wrench® Feature Map
Perform specialized testing Access the Digital Wrench® and adjustment functions System Help. service reports. Print the current screen as a Open the ASSERT ASK formatted printout. form. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.43 © Copyright Polaris Inc.
Page 52: Engine Controller Reprogramming (Reflash)
– Avoid using the PC while reprogramming is in 9. Copy the Request Code in Digital Wrench®. progress. 10. Open a web browser and log on to your Polaris dealer • Understand the Process website (www.polarisdealers.com). Review the Digital Wrench® System Help before you 11.
Page 53: Polaris Mobile Digital Wrench® (Pmdw)
Wrench® software. complete list of compatible vehicles. You can download the PMDW app on your Android device from the Polaris dealer website. From the Service and Warranty drop-down, select Digital Wrench, and then click Mobile Digital Wrench App Download. MINIMUM SPECIFICATIONS FOR AN- DROID DEVICES •...
Page 54: Engine Electrical Diagnostics
0 to 9. This number represents the total number of trouble code present (example: 2 means there are 3 codes present). 5. Press MODE to exit to the settings menu. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.46 © Copyright Polaris Inc.
Page 55: Master Trouble Code List
P0106 Voltage Above Normal, Or Shorted To High Source P0108 Manifold Absolute Pressure Sensor Voltage Too Low P0107 Mechanical System Not Responding Or Out Of Adjustment P1106 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.47 © Copyright Polaris Inc.
Page 56 Voltage Below Normal, Or Shorted To Low Source P1568 Data Valid But Above Normal Operating Range - Moderately Severe P1571 Level Data Valid But Below Normal Operating Range - Moderately Severe P1573 Level 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.48 © Copyright Polaris Inc.
Page 57 Mechanical System Not Responding Or Out Of Adjustment P0016 Camshaft Position Sensor Abnormal Frequency Or Pulse Width Or Period P0340 Voltage Above Normal, Or Shorted To High Source P1739 Tachometer Driver Circuit 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.49 © Copyright Polaris Inc.
Page 58 Data Erratic, Intermittent Or Incorrect C103D Wheel Speed Sensor (Rear or Voltage Above Normal, Or Shorted To High Source C113D Rear Left) Voltage Below Normal, Or Shorted To Low Source C123D 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.50 © Copyright Polaris Inc.
Page 59 EFI Relay Control Circuit 1485 Current Below Normal Or Open Circuit P0685 Voltage Above Normal P0694 1557 Fan Driver 2 Voltage Below Normal, Or Shorted To Low Source P0693 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.51 © Copyright Polaris Inc.
Page 60 Data Valid But Below Normal Operational Range - Most Severe Level P17AE ECU Output Supply Voltage 3 3599 Voltage Above Normal, Or Shorted To High Source P17AA Voltage Below Normal, Or Shorted To Low Source P17AB 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.52 © Copyright Polaris Inc.
Page 61 Data Valid But Below Normal Operating Range - Least Severe Level P0174 Data Erratic, Intermittent Or Incorrect P1684 520206 Reverse Alarm Voltage Above Normal, Or Shorted To High Source P1682 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.53 © Copyright Polaris Inc.
Page 62 Current Below Normal Or Open Circuit C1029 ABS Solenoid (Front Right Out) 520257 Condition Exists C1329 Voltage Above Normal, Or Shorted To High Source C1020 520260 ABS Motor 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.54 © Copyright Polaris Inc.
Page 63 ECU Monitoring Error (Level 3) 520287 Condition Exists P1542 ECU Monitoring of Injection Cut Off 520288 (Level 1) ECU Monitoring of Injection Cut Off Condition Exists P1543 520289 (Level 2) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.55 © Copyright Polaris Inc.
Page 64 524067 Drive Mode Select Switch Voltage Below Normal, Or Shorted To Low Source P153B Operator Presence Switch Voltage Above Normal, Or Shorted To High Source P251C 524070 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.56 © Copyright Polaris Inc.
Page 65 EPS Fault Lamp Driver Circuit 524085 Voltage Above Normal, Or Shorted To High Source C106D EPS SEPIC Voltage Error 524086 Voltage Below Normal, Or Shorted To Low Source C106E 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.57 © Copyright Polaris Inc.
Page 66: Cylinder Misfire Detection
4000 engine revolutions (i.e. 4000 RPM for one minute) without a significant misfire being detected. Once this condition is met, the check engine light will turn off and the code(s) will show as historic. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.58 © Copyright Polaris Inc.
Page 67: Fluid Leaks
• If a fluid is contaminated with metal or debris, suspect that there is a mechanical failure causing the fluid contamination. Refer to the Service Manual information related to the system in question. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.59 © Copyright Polaris Inc.
Page 68: Fuel System Diagnostics
• Intake air leak (throttle shaft, intake ducts, air box cover) • Spark plug erosion / fouling • Faulty oxygen sensor • Engine runs hot • Surging • High / Erratic idle 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.60 © Copyright Polaris Inc.
Page 69 • High percentage of cylinder leakdown (worn engine) • Low compression (worn engine) • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.61 © Copyright Polaris Inc.
Page 70: Pvt System Diagnostics
Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.62 © Copyright Polaris Inc.
Page 71 Replace belt. Refer to belt burnt troubleshooting Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.63 © Copyright Polaris Inc.
Page 72: Pvt System Overheating / Diagnosis
PVT system. than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified Clutch malfunction. technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty fuel Poor engine performance.
Page 73: Transmission Diagnostics
• If the bellcrank moves freely, manually select each gear range at the transmission bellcrank and test ride vehicle. If it functions properly then there is likely still an outside concern causing the issue. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.65 © Copyright Polaris Inc.
Page 74: Final Drive Diagnostics
Driveshaft (Half Shaft) operation can cause various customer concerns. For more information related to Driveshaft concerns or failures CLICK HERE to view the “Half Shaft Analysis” poster. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.66 © Copyright Polaris Inc.
Page 75: Brake System Diagnostics
• Brake Pad wear (uneven / unusual wear) exceeds service limit) • Brake Disc damaged VEHICLE VIBRATION (VIBRATION FELT THROUGH ENTIRE VEHICLE / CHASSIS WHILE BRAKING) • Worn Suspension components • Alignment issues 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.67 © Copyright Polaris Inc.
Page 76: Caliper Overheats (Brakes Drag)
• Failed brake hose / line • Caliper pistons sticking • Improper assembly of brake system components • Failed master cylinder • Faulty distribution block (INTL models only ) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.68 © Copyright Polaris Inc.
Page 77: Steering / Suspension Diagnostics
→ Check wiring from Connector to Ignition Switch 12 VDC on Pin 3 of the 8 pin EPS Connector? Circuit ↓ Begin Digital Wrench EPS Troubleshooting Procedure 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.69 © Copyright Polaris Inc.
Page 78: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)
Cluster EPS “Non Instrument during MIL lamp Functional Trouble- Cluster Instrument and MIL shooting Power Up Cluster ON” Procedure Self Test? Power Up. ↑ ← ← ↓ ← 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.70 © Copyright Polaris Inc.
Page 79: Eps Troubleshooting (Using Digital Wrench®)
If inverter temperature error code is present, replace Power Steering Module. If error is not present, Module is OK. EPS inverter temperature can be checked using Digital Wrench. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.71 © Copyright Polaris Inc.
Page 80: Shock Analysis
(weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock. MISTING OR WEEPAGE LEAKAGE 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.72 © Copyright Polaris Inc.
Page 81: Electrical Diagnostics
DIGITAL MULTI-METER (DMM) NOTES Testing For A Short To Ground page 1.75 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 1.76...
Page 82: Connector Probing Guidelines
To avoid causing damage, use of the appropriate Back probing is typically not advisable on sealed adapters is required. Most terminals used on Polaris connectors, as it can easily cause damage to the wire, machines can be tested using terminal test kit PV–...
Page 83: Testing Continuity / Resistance
9. If the DMM reads OL, there is no short to ground. Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltage page 1.76 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.75 © Copyright Polaris Inc.
Page 84: Testing For A Short To Voltage
For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 1.76 © Copyright Polaris Inc.
Page 86: Current Draw - Key Off
Maximum of .01 DCA (10 mA) Charging system damage will occur if incompatible components are installed. Always reference the Polaris 9. If over 10 milliamps, go to the fuse block and start Electronic Parts Catalog for the proper part numbers.
Page 91: Maintenance
SERVICE NOTES - MAINTENANCE Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Page 92: Maintenance Specifications
Refer to the warning tire pressure decal applied to the vehicle. MODEL FRONT REAR RANGER 10 PSI (69 kPa) 14 PSI (96.5 kPa) 1000 RANGER 16 PSI (110 kPa) 20 PSI (138 kPa) 1000 Crew 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 93: Service Products
Premium All-Season 2871423 Grease (14 oz) (10 count) Premium U-Joint Lubricant (3 oz) (24 2871515 count) Premium U-Joint Lubricant (14 oz) (10 2871551 count) Dielectric Grease 2871329 (Nyogel™) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 94: 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 95: Pre-Ride Inspection
Auxiliary Brake (if equipped) Inspect / adjust as needed Inspect / clean often PVT Outlet Duct Screen Spark Arrester Inspect / clean after operating in mud and water 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 96: Maintenance Intervals
100 hours or 1 year after initial break-in oil change 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual ©...
Page 97 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual...
Page 98 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.10...
Page 99 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.11...
Page 100 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.12...
Page 101 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.13...
Page 102 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.14...
Page 103 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.15...
Page 104 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.16...
Page 105 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.17...
Page 106 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.18...
Page 107 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.19...
Page 108 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.20...
Page 109 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.21...
Page 110 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.22...
Page 111 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.23...
Page 112 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.24...
Page 113 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.25...
Page 114 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.26...
Page 115 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 116: Maintenance Quick Reference
Duty Full Synthetic - On Front Side of Engine months, whichever comes first Check level daily; change Engine Coolant Polaris 50 / 50 Extended Life Maintain coolant level in coolant every two years - Under Front Hood Antifreeze coolant reservoir bottle * More often under severe use, such as operation in water or under severe loads.
Page 117 (52 fl oz Transmission Gearcase ( 1550 mL)) Lubricant * More often under severe use, such as operation in water or under severe loads. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.29 © Copyright Polaris Inc.
Page 118: Grease Lubrication Points
Grease fittings every 500 miles (800 km); Grease before long periods of Propshaft Yoke Premium U-Joint Lubricant Grease fitting storage, and after thoroughly washing or submerging the vehicle BASE CREW 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.30 © Copyright Polaris Inc.
Page 119: Engine Maintenance
7. Recheck the oil level and ensure if is within the SAFE range on the dipstick. 8. When finished, reinstall dipstick and lock the lever. Lower the cargo box and secure in position. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.31 © Copyright Polaris Inc.
Page 120: Engine Oil And Filter Service
6. Pull up on the cargo box release lever to tilt the box. PS-4 10W-50 Extreme Duty Full Synthetic Ambient Temp Range: 0° F to 120° F Capacity: 2.5 Qt. (2.4 L) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.32 © Copyright Polaris Inc.
Page 121: Valve Clearance Inspection
20. When finished, reinstall the oil fill cap, oil dipstick and lock the lever. 2. Measure the valve clearance using a feeler gauge. 21. Dispose of used oil and filter properly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.33 © Copyright Polaris Inc.
Page 122: Cam Chain Tensioner Inspection
It should move freely. If it does not move freely, replace the tensioner assembly. TORQUE Battery Terminal Fastener: 40 in-lbs (5 Nm) 5. Start the engine to ensure proper operation. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.34 © Copyright Polaris Inc.
Page 123 7. Install the plunger bolt. Torque fastener to specification. TORQUE Plunger Bolt: 15 ft-lbs (20 Nm) 8. Turn the engine over by hand to ensure proper chain tension is applied. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.35 © Copyright Polaris Inc.
Page 124: Cooling System Maintenance
CAUTION Overheating of engine could occur if air is not fully purged from system. Polaris Premium 50/50 Extended Life coolant is already premixed and ready to use. Do not dilute with water. COOLANT STRENGTH / TYPE Test the strength of the coolant using an antifreeze hydrometer.
Page 125: Coolant Level Inspection
“MAX” Recommended Anti-Freeze/Coolant: and “MIN” levels indicated on the recovery bottle. Polaris 50 / 50 Extended Life Antifreeze 5. Reinstall the recovery bottle cap. 6. If coolant was required, start engine and check for leaks.
Page 126: Cooling System Hose Inspection
(PN 2880513) (Gallon) CAUTION Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness. Use of a high-pressure washer is not recommended. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.38 © Copyright Polaris Inc.
Page 127: Air Intake And Exhaust Maintenance
2. Use a twisting and rocking motion to remove the air filter. 3. Install the airbox cover and latch the retaining clips 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.39 © Copyright Polaris Inc.
Page 128: Engine Crankcase Breather Hose Inspection
Follow the breather hose from the crankcase fitting to the airbox IMPORTANT Ensure hoses are not kinked or pinched. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.40 © Copyright Polaris Inc.
Page 129: Exhaust Spark Arrestor Inspection
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: 10 ft-lbs (14 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.41 © Copyright Polaris Inc.
Page 130: Exhaust Heat Shield Inspection
Closeoff Shield Lower Headpipe Shield Overlaps under the Upper Shield Inner Silencer Shield Outer Silencer Shield Inner Headpipe Shield Upper Headpipe Shield Overlaps over the Lower Shield 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.42 © Copyright Polaris Inc.
Page 131: Fuel System Maintenance
Replace line if necessary. 3. Ensure fuel lines are properly routed and retained. Refer to Fuel Line Routing page 5.5. CAUTION Ensure lines are not kinked or pinched. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.43 © Copyright Polaris Inc.
Page 132: Fuel Tank Vent Line Inspection
• EVAP MODELS: 2. Be sure vent line is routed properly and secured. IMPORTANT Be sure vent line is not kinked or pinched. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.44 © Copyright Polaris Inc.
Page 133: Pvt System Maintenance
If the vehicle has ingested a large amount of water into the PVT system and has not been operated for a period of time, be sure to check the PVT system components for water damage. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.45 © Copyright Polaris Inc.
Page 134: Transmission And Front Gearcase Maintenance
Transmission Fill / Drain Plug: TORQUE 12 ft-lbs (16 Nm) Transmission Fill / Drain Plug: 12 ft-lbs (16 Nm) 8. Check for leaks. Dispose of used lubricant properly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.46 © Copyright Polaris Inc.
Page 135: Shift Cable Inspection
• AWD light displayed on instrument cluster • Ratcheting noise on deceleration • Inability to engage into a gear • Excessive gear lash (noise) • Gear selector moving out of desired range 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.47 © Copyright Polaris Inc.
Page 136 NOTICE For optimal shift cable adjustment, the gap measurements in High and Park should be equal. This will ensure the shifter will not contact the dash. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.48 © Copyright Polaris Inc.
Page 137: Front Gearcase Fluid Level Inspection
It is important to follow the front gearcase maintenance intervals described in the Periodic Maintenance Chart. The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.49 © Copyright Polaris Inc.
Page 138: Front Gearcase Fluid Replacement
Maintain the fluid level even with the bottom threads of the fill plug hole. FLUID CAPACITY Recommended Front Gearcase Fluid: Polaris Demand Drive Fluid (PN 2877922) (Quart) Capacity:8.5 oz (250 mL) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.50...
Page 139 7. Reinstall fill plug with a new O-ring and torque to specification. TORQUE Front Gearcase Fill / Drain Plug: 10 ft-lbs (14 Nm) 8. Check for leaks. Dispose of used fluid properly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.51 © Copyright Polaris Inc.
Page 140: Final Drive Maintenance
CAUTION Ensure the vehicle is properly supported and does not tip or fall. 5. Remove the wheel nuts and remove the wheel 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.52 © Copyright Polaris Inc.
Page 141: Tire Inspection
Operating with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control. Worn tires can cause an accident. Always replace tires when the usable tread depth has worn out. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.53 © Copyright Polaris Inc.
Page 142: Steering Maintenance
WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.54...
Page 143: Tie Rod End Inspection
• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut). 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.55 © Copyright Polaris Inc.
Page 144: Wheel Toe Adjustment
Damage may not be immediately apparent if done incorrectly. 4. After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 13 ft-lbs (18 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.56 © Copyright Polaris Inc.
Page 145: Suspension Maintenance
Vehicle loads effect suspension spring pre-load requirements. Use Spanner Wrench to adjust pre-load as necessary to avoid bottoming of the shocks. Shock Spanner Wrench: 2871095 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.57 © Copyright Polaris Inc.
Page 146: Brake System Maintenance
1. Locate master cylinder reservoir in the front left- leakage around the master cylinder fittings and the hand wheel well area. Clean reservoir cover brake caliper fittings. thoroughly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.58 © Copyright Polaris Inc.
Page 147 12. Tighten bleeder screw and remove bleeder hose. Torque bleed screw to specification. Polaris DOT 4 Brake Fluid P/N: TORQUE 2872189 Caliper Bleed Screws: 4 ft-lbs (5.4 Nm) 5.
Page 148: Brake Pad Inspection
MEASUREMENT Brake Pad Thickness (Minimum): .120 in (3 mm) BRAKE DISC INSPECTION 1. Visually inspect disc for scoring, scratches or gouges. Replace disc if any are evident. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.60 © Copyright Polaris Inc.
Page 149: Electrical Maintenance
BatteryMINDer® 2012 AGM - 2 AMP charger. Batteries will self discharge more rapidly when stored in extreme temperatures. BatteryMINDer® 2012 AGM - 2 AMP battery charger 2830438 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.61 © Copyright Polaris Inc.
Page 150: Battery Service
5. Push the hold down clamp towards the rear of the vehicle to release and lift straight out of the vehicle to remove. 6. Lift the battery straight up to remove from the vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.62 © Copyright Polaris Inc.
Page 151 5. Install the storage bin under the passenger seat. TORQUE 6. Engage the passenger seat in the seat brackets and rotate until engaged in the seat grommet. Battery Hold Down Clamp: 6 ft-lbs (8 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.63 © Copyright Polaris Inc.
Page 152: Chassis / Engine Electrical Ground
4. Remove and clean all ground terminals as necessary. 5. Ensure all chassis grounds are properly torqued. TORQUE Chassis Ground: 8 ft-lbs (11 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 2.64 © Copyright Polaris Inc.
Page 155: Engine Service Specifications
Valve Seat - Contacting Width - Exhaust 0.0787 ± 0.0039“ (2.0 ± 0.10 mm) 0.0945" (2.4 mm) Valve Seat 30.0° ± 1.5° Valve Seat Angles 45.0° ± 0.5° 60.0° ± 1.5° 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 156 COLD: 60° - 90° F (16° - 32° C) MAX: 85 PSI MIN: 60 PSI Oil Pressure @ 6250 RPM HOT: 249°-265° F (120° - 129° C) MAX: 67 PSI 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 157: Engine Torque Sequences
M8 Bolts: M6 Bolts: M6 Bolts: 9 ft-lbs (12 Nm) CAM CARRIER VALVE COVER Camshaft Carrier Bolts Valve Cover Bolts 7 ft-lb (10 Nm) 7 ft-lbs (10 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 158 9 ft-lbs (12 Nm) M6 Cylinder Head Bolts Step 4: 7 ft-lb (10 Nm) STATOR COVER OIL COOLER Stator Cover Bolts Oil Cooler 9 ft-lbs (12 Nm) 7 lb-ft (10 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 159: Valve Lash - Tappet Selection
(mm) 1. Subtract the actual valve lash on the engine from the valve lash specification (i.e. 0.29 mm – 0.20 mm) = 0.09 mm. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 160: Bearing Selection Identification Letters And Numbers
Number (six numbers) 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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 161: Connecting Rod Bearing Selection
Yellow bearing for Main #4 Blue Blue Green BEARING SELECTION CHART — MAIN BEARINGS Blue Green Yellow Crankshaft Green Yellow Yellow Code Blue Blue Green Case Blue Green Yellow Green Yellow Yellow 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 162: Intake Service
Intake Hose (Airbox to Throttle Body) Intake Duct Clamp 35 in-lbs (4 Nm) Engine Breather Hose Clamp Engine Breather Hose Airbox Housing Air Filter Push Rivet Airbox Cover 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.10 © Copyright Polaris Inc.
Page 163: Airbox Service
Torque to specification. 4. Remove the two fasteners securing the airbox to the chassis. TORQUE Airbox Fasteners: 44 in-lbs (5 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.11 © Copyright Polaris Inc.
Page 164: Intake Duct Service
2. Loosen the clamp at the airbox and remove the duct 35 in-lbs (4 Nm) from the airbox. 5. Install the ignition coil. Refer to Ignition Coil Service page 4.18. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.12 © Copyright Polaris Inc.
Page 165 4. Carefully remove the duct from the lower closeoff panel. CAUTION Use care not to tear the intake duct when removing from the panel. 2. Carefully push the grommets through the side bezel. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.13 © Copyright Polaris Inc.
Page 166 3. Instal the duct on the airbox and tighten the clamp to specification. TORQUE Intake Duct Clamp: 35 in-lbs (4 Nm) 4. Install the side bezel cover. Refer to Side Bezel Cover Service page 11.38. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.14 © Copyright Polaris Inc.
Page 167: Throttle Body Service
Intake Duct Service page 3.12. 1. Inspect the throttle body gasket and replace as 5. Perform ETC learn procedure. Refer to ETC Learn needed. Procedure page 4.12. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.15 © Copyright Polaris Inc.
Page 168: Intake Manifold Service
1. Install the manifold in the vehicle. 2. Install the lower manifold fastener and nut on the transmission bracket. Do not torque at this time. 4. Loosen the intake manifold clamps. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.16 © Copyright Polaris Inc.
Page 169 7. Install the intake duct from the airbox to the throttle Lower Intake Manifold Fastener: body. Refer to Intake Duct Service page 3.12. 18 ft-lbs (24 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.17 © Copyright Polaris Inc.
Page 170: Intake Manifold Adapter Service
3. Install the Intake Manifold. Refer to Intake Manifold Service page 3.16. INSTALLATION 1. Inspect the gasket surface on the adapters and replace the adapter as needed. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.18 © Copyright Polaris Inc.
Page 171: Exhaust Service
Lower Headpipe Heat Shield Headpipe Gasket Headpipe Exhaust Fastener: M8 x 1.25 x 22 22 ft-lbs (30 Nm) 42 in-lbs (5 Nm) Heat Shield Fastener: M6 x 1.0 x 25 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.19 © Copyright Polaris Inc.
Page 172: Muffler Service
2. Disconnect the exhaust muffler springs from the chassis. 3. Inspect the muffler flange gasket and replace as needed. 3. Pull the muffler isolators from the chassis and remove the muffler assembly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.20 © Copyright Polaris Inc.
Page 173 ENGINE / COOLING / EXHAUST 4. Install the exhaust spring bolts and torque to specification. TORQUE Exhaust Spring Fasteners: 21 ft-lbs (28 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.21 © Copyright Polaris Inc.
Page 174: Headpipe Service
Discard the headpipe gasket. 4. Remove the two fasteners securing the lower heat shield to the headpipe, and remove the heat shield. INSTALLATION 1. Install a new headpipe gasket. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.22 © Copyright Polaris Inc.
Page 175 6 ft-lbs (8 Nm) 6. Install the Exhaust Muffler. Refer to Muffler Service page 3.20. 7. Install the Oxygen Sensor. Refer to Oxygen Sensor Service page 4.27 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.23 © Copyright Polaris Inc.
Page 176: Engine Service
• Counterbalance Shaft / Bearings • Crankcase • Crankshaft / Main Bearings • Cylinder • Oil Pump / Oil Pump Sprocket or Chain • Piston / Rings 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.24 © Copyright Polaris Inc.
Page 177 22 ft-lbs (30 Nm) 4. Remove the lift or jack supporting the weight of the engine. 5. Install the skid plate. Refer to Skid Plate Service page 11.35. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.25 © Copyright Polaris Inc.
Page 178: Crankshaft Pto Seal Replacement
Use care not to scratch the crankcase while removing seal. 3. Inspect the crankcase and crankshaft surfaces for any burrs or scratches that could damage the new seal or prevent it from sealing properly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.26 © Copyright Polaris Inc.
Page 179: Engine Removal & Installation
8. Disconnect all electrical connectors and remove the harness from the engine. Refer to Engine Harness Routing page 4.3. CAUTION Ensure the engine is properly supported with an engine hoist before proceeding. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.27 © Copyright Polaris Inc.
Page 180 11. Remove the nuts and fasteners securing the engine to the front engine mount. 12. Carefully lift the engine straight up and out of the vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.28 © Copyright Polaris Inc.
Page 182 Service page 3.80. 14. Install the exhaust headpipe. Refer to Headpipe Service page 3.22. 15. Install the inner clutch cover. Refer to Inner PVT Cover Service page 6.11. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.30 © Copyright Polaris Inc.
Page 183 Fuel Supply Line Service page 5.8. 17. Install the intake manifold. Refer to Intake Manifold Service page 3.16. 18. Connect the battery. Refer to Battery Service page 2.62. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.31 © Copyright Polaris Inc.
Page 184: Engine Timing
Adjustment page 3.33. 5. Install the valve cover. Refer to Valve Cover Service page 3.35. 6. Install the Crankshaft Position Sensor. Refer to CPS Replacement page 4.11. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.32 © Copyright Polaris Inc.
Page 186 Adjust as needed. 9. Install the valve cover. Refer to Valve Cover Service page 3.35. 10. Install the Crankshaft Position Sensor. Refer to CPS Replacement page 4.11. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.34 © Copyright Polaris Inc.
Page 187: Engine Service - Top End
2. Install the valve cover on the engine. the valve cover. 3. Install the fasteners and new rubber isolators 3. Remove the valve cover gasket and discard. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.35 © Copyright Polaris Inc.
Page 188: Valve Clearance Adjustment
3. Record the three digit number on the bottom of the valve tappet. 4. Select the appropriate valve tappet. Refer to Valve Lash - Tappet Selection page 3.7. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.36 © Copyright Polaris Inc.
Page 189: Cam Chain Tensioner Service
It should move freely. If it does not 8. Finish engine assembly. Refer to Camshaft Service move freely, replace the tensioner assembly. page 3.39. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.37 © Copyright Polaris Inc.
Page 190: Camshaft Sprocket Service
2. Reinstall the valve cover. Refer to Valve Cover Service page 3.35. TORQUE Plunger Bolt: 15 ft-lbs (20 Nm) 8. Turn the engine over by hand to ensure proper chain tension is applied. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.38 © Copyright Polaris Inc.
Page 191: Camshaft Service
3. Lift the camshaft straight up to remove from the cylinder head. 3. Torque the camshaft carriers in the sequence below. TORQUE Camshaft Bearing Caps: 7 ft-lb (10 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.39 © Copyright Polaris Inc.
Page 192: Camshaft Inspection
2.0257 - 2.0294” (51.45-51.55 mm) Service Limit: 2.0237 (51.40 mm) CAMSHAFT JOURNAL 1. Visually inspect each camshaft journal for scoring, TORQUE wear or damage. Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.40 © Copyright Polaris Inc.
Page 193: Cylinder Head Removal And Installation
Calculated Camshaft Oil Clearance: 0.0018 - 0.0035” (0.046 - 0.088 mm) Service Limit: .0047" (0.119 mm) 7. Remove the Camshaft Sprocket. Refer to Camshaft Sprocket Service page 3.38. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.41 © Copyright Polaris Inc.
Page 194 Ensure the cylinder head is fully seated on the cylinder Fasteners are one time use. Discard after removing. head dowels. 10. Refer to Cylinder Head Inspection page 3.49 before reassembly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.42 © Copyright Polaris Inc.
Page 195 Level Inspection. 12. Fill and bleed the cooling system. Refer to Coolant Service page 3.80. 5. Install the Camshaft Sprocket. Refer to Camshaft Sprocket Service page 3.38. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.43 © Copyright Polaris Inc.
Page 196: Valve Service
4. Remove the two valve keepers 7. If reusing valve, perform valve inspection. Refer to Valve Inspection page 3.46. INSTALLATION 1. Carefully slide the valve into the cylinder head through the bottom. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.44 © Copyright Polaris Inc.
Page 197 4. Install the two valve keepers 5. Install the cylinder head. Refer to Cylinder Head Removal and Installation page 3.41. 6. Install the camshaft. Refer to Camshaft Service page 3.39. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.45 © Copyright Polaris Inc.
Page 198: Valve Inspection
Valve Guide I.D.: 0.2741 - 0.2747" (6.963 - 6.978 mm) 7. Be sure to measure each guide and valve combination individually. NOTICE The valve guides cannot be replaced. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.46 © Copyright Polaris Inc.
Page 199: Valve Seat Reconditioning
2. Apply cutting oil to valve seat and cutter. valve face or slightly above, and must be the proper width 3. Place 46° cutter on the pilot and make a light cut. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.47 © Copyright Polaris Inc.
Page 201: Cylinder Head Inspection
2. Visually inspect cylinder head gasket surface and MEASUREMENT combustion chamber for cracks or damage. Pay Cylinder Head Warp Limit: close attention to areas around spark plug and valve seats. 0.0039″ (0.1 mm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.49 © Copyright Polaris Inc.
Page 202: Engine Service - Bottom End
TORQUE Oil Filter Adapter Fasteners: 21 ft-lbs (28 Nm) INSTALLATION 1. Replace the oil filter adapter gasket upon reassembly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.50 © Copyright Polaris Inc.
Page 203: Oil Sump Service
3. Install the thirteen M6 oil sump fasteners torque to specification. 5. Remove the oil sump from the engine. TORQUE Oil Sump Fasteners (M6): 9 ft-lbs (12 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.51 © Copyright Polaris Inc.
Page 204: Oil Pump Service
5. Fill the engine oil. Refer to Engine Oil Level 3. Remove the two dowels Inspection. 6. Install the skid plate. Refer to Skid Plate Service page 11.35. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.52 © Copyright Polaris Inc.
Page 205 Ensure the oil pump pickup is clean and free of debris. install the sprocket bolt and case plug . Torque to specification. TORQUE Oil Pump Sprocket: 7 ft-lbs (10 Nm) Case Plug: 22 ft-lbs (30 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.53 © Copyright Polaris Inc.
Page 206: Upper Crankcase Service
7. Remove the two M8 upper crankcase fasteners from the top of the motor. Oil Pump Fasteners: 7 ft-lbs (10 Nm) 5. Install the oil sump. Refer to Oil Sump Service page 3.51. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.54 © Copyright Polaris Inc.
Page 207 11. Gently pry the lower crankcase apart from the engine and remove. INSTALLATION 1. Clean the gasket surface of the engine. TORQUE Upper Crankcase Fasteners (M6): 7 ft-lbs (10 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.55 © Copyright Polaris Inc.
Page 208 13. Install the oil filter adapter. Refer to Oil Filter Adapter Service page 3.50. 14. Install the engine assembly. Refer to Engine Removal & Installation page 3.27. TORQUE Upper Crankcase Fasteners (M8): 26 ft-lbs (35 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.56 © Copyright Polaris Inc.
Page 209: Balance Shaft Service
Service Limit: 1.4921" (37.900 mm) 6. Install the upper crankcase. Refer to Upper Crankcase Service page 3.54. 4. Inspect the balance shaft gear teeth for damage. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.57 © Copyright Polaris Inc.
Page 210: Crankshaft Service / Inspection
Crankshaft Maximum Runout: Less than .001″ (0.025 mm) 4. Visually inspect surface of crankshaft main and connecting rod journals. Replace crankshaft if any journal is scratched or pitted. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.58 © Copyright Polaris Inc.
Page 211 8. Whether installing a new crankshaft or re-installing the original, refer to the bearing selection chart provided in the “Crankshaft Main Bearing Selection” page 3.9 and “Connecting Rod Bearing Selection” page 3.9 procedures. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.59 © Copyright Polaris Inc.
Page 212 ENGINE / COOLING / EXHAUST INSTALLATION 6. Apply Polaris PS-4 engine oil to each rod bearing journal and main bearing journal of crankshaft. 1. Rotate the engine so the cylinder is facing down. 2. Clean the bearing bore surfaces of upper crankcase (main bearings), connecting rods and connecting rod caps.
Page 213 Step 1: 9 ft-lbs (12 Nm) Step 2: 22 ft-lbs (30 Nm) Step 3: Tighten additional 90° 15. Install the balance shaft. Refer to Balance Shaft Service page 3.57. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.61 © Copyright Polaris Inc.
Page 214: Cylinder / Piston Service
1. Apply clean engine oil to each piston assembly, cylinder bore and bottom tapered portion of each cylinder sleeve. 2. Verify that all ring end gaps are correctly located on each piston. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.62 © Copyright Polaris Inc.
Page 215 6. Clean base gasket sealing surface on cylinder and crankcase to remove all oil and grease. IMPORTANT Base gasket and surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.63 © Copyright Polaris Inc.
Page 216: Crankcase Inspection
4. Be sure oil passages are clean and free of any cleaning solvent. NOTICE Always replace plain bearings when the crankcase or connecting rods have been disassembled. Refer to Bearing Selection Identification Letters and Numbers. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.64 © Copyright Polaris Inc.
Page 217: Cylinder Inspection
3. Inspect taper and out of round with a dial bore gauge. .001″ (0.025 mm) Cylinder Out of Round: .001″ (0.025 mm) MEASUREMENT Standard Bore Size: 3.6614 ± .0003" (93 mm ± 0.008 mm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.65 © Copyright Polaris Inc.
Page 218: Piston Disassembly / Inspection
DO NOT apply heat to piston rings or a loss of radial MEASUREMENT tension could result. Piston Pin O.D.: 0.7872 - 0.7874" (19.995 - 20.004 mm) Service Limit: 0.7864" (19.975 mm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.66 © Copyright Polaris Inc.
Page 220 0.010 - 0.040" (0.25 - 1.02 mm) Service Limit: 0.0433" (1.1 mm) NOTICE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.68 © Copyright Polaris Inc.
Page 221: Connecting Rod Inspection
(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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.69 © Copyright Polaris Inc.
Page 222: Stator Cover Service
DO NOT place fingers between cover and crankcase at any time during the removal / installation process or injury could result. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.70 © Copyright Polaris Inc.
Page 223 DO NOT place fingers between cover and crankcase at any time during the removal / installation process or injury could result. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.71 © Copyright Polaris Inc.
Page 224: Flywheel Service
4. Fully install Flywheel Puller (PA-49316) on the threads of the flywheel. NOTICE Puller is left hand threaded. Turn the flywheel puller counterclockwise to install. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.72 © Copyright Polaris Inc.
Page 225: Starter One-Way Clutch Service
Loctite cures with time, the longer the unit is able to stand before starting the engine, the stronger the joint will be. 8. Install the starter torque limit gear as an assembly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.73 © Copyright Polaris Inc.
Page 226 If any starter one-way clutch component is worn or damaged, replace the clutch and starter gear as an assembly. TORQUE One-Way Clutch Retaining Screws: 9 ft-lbs (12 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.74 © Copyright Polaris Inc.
Page 227: Starter One-Way Clutch Inspection
Starter One-Way Clutch Service page 3.73. 5. Install the flywheel. Refer to Flywheel Service page 3.72. IMPORTANT Ensure the starter gear rotates in the clockwise direction only. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.75 © Copyright Polaris Inc.
Page 228: Cooling System Service
Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
Page 229: Cooling System Assembly View
22 in lbs (4.5 Nm) Retainer Bolt: M6: x 1.0 x 40 44 in-lbs (5.0 Nm) Coolant Hose Clamp 35 in-lbs (4 Nm) Coolant Hose Retention Clip Upper Coolant Hose Assembly 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.77 © Copyright Polaris Inc.
Page 230 35 in-lbs (4 Nm) Water Pump Fastener: M6 x 1.0 x 35 7 ft-lbs (10 Nm) Retention Clip Engine Outlet Hose Retention Clip Oil Cooler Inlet Hose Thermostat 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.78 © Copyright Polaris Inc.
Page 231 Three Way Valve Bracket Fastener: M6 x 1.0 x 20 6 ft-lbs (8 Nm) Oil Cooler Inlet Hose Accessory Cooler Hose Coolant Hose Clamp 35 in-lbs (4 Nm) Coolant Hose Retention Clip 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.79 © Copyright Polaris Inc.
Page 232: Coolant Service
Always fan has cycled two times. allow the engine to cool before removing the pressure cap. 2. Remove the hood from the front cab. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.80 © Copyright Polaris Inc.
Page 233: Cooling System Pressure Test
10. Remove the pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck. 11. 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 234: Radiator Cap Pressure Test
The cooling system is under pressure and serious . Remove the two radiator support brackets burns may result. Allow the engine to cool before servicing. 5. Remove the upper radiator hose from the radiator. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.82 © Copyright Polaris Inc.
Page 235 35 in-lbs (4 Nm) 3. Connect the small radiator bypass hose 8. Lift the radiator up to remove from the vehicle. 9. Inspect fan blades for damage. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.83 © Copyright Polaris Inc.
Page 236: Radiator Fan Removal
6. Fill and bleed the cooling system. Ensure no leaks are present. Refer to Coolant Service page 3.80. 7. Install the radiator access flap up. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.84 © Copyright Polaris Inc.
Page 237: Engine Oil Cooler Service
Catch and properly dispose of any escaping oil or engine using the four oil cooler fasteners . Torque coolant. to specification. TORQUE Oil Cooler Fasteners: 7 lb-ft (10 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.85 © Copyright Polaris Inc.
Page 238: Thermostat Replacement
6. Remove the cargo box access panel. Level Inspection. 7. Using an 8 mm swivel socket and long extension, remove the front bolt retaining the thermostat cover. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.86 © Copyright Polaris Inc.
Page 239: Water Pump Service
NOTICE If the water pump does not readily remove, use a twisting and rocking motion to remove from the engine. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.87 © Copyright Polaris Inc.
Page 240 4. Remove impeller from water pump shaft. 5. Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.88 © Copyright Polaris Inc.
Page 241 Water Pump Impeller Bolt: 7 ft-lbs (10 Nm)(Apply Loctite® 204™ to bolt threads) 17. Clean cover and housing gasket surfaces 18. Install a new water pump cover gasket 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.89 © Copyright Polaris Inc.
Page 242 ENGINE / COOLING / EXHAUST WATER PUMP ASSEMBLY VIEW Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.90 © Copyright Polaris Inc.
Page 243 4. Use a shop light to illuminate the water pump drive access hole in engine crankcase and note orientation TORQUE of the water pump drive slot Water Pump Mounting Fasteners: 7 ft-lbs (10 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.91 © Copyright Polaris Inc.
Page 244: Heater Valve Service
2.62. TORQUE Heater Valve Fasteners: 6 ft-lbs (8 Nm) 4. Fill and bleed the cooling system. Verify no leaks are present. Refer to Coolant Service page 3.80. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.92 © Copyright Polaris Inc.
Page 245: Troubleshooting
If diagnosing a single cylinder Test results are based on the use of the recommended engine, this must be compared to a known good engine oil (Polaris PS-4 5W-50 Full Synthetic or PS-4 engine. 10W-50 Extreme Duty Full Synthetic) at operating temperature, and may vary considerably if any other oil is used or if engine is not up to temperature.
Page 246 Test and compare all cylinders before attempting further repairs. Leak percentage should be consistent between cylinders. A 5 to 10 percent variance between cylinders would likely be considered normal. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 3.94 © Copyright Polaris Inc.
Page 249: Engine Harness
Box Harness Connector Throttle Body Connector Oxygen Sensor Connector T-MAP Sensor Box Lift Actuator Connector Zip Tie (Oxygen sensor harness to main harness) Tree clip (Into Intake Manifold) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 250 ENGINE ELECTRICAL INJECTOR HARNESS DESCRIPTION PTO Fuel Injector Connector MAG Fuel Injector Connector Tree Clip (Into Intake Manifold) Coolant Temperature Sensor Connector Tree Clip (Into PVT Duct) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 251 ENGINE ELECTRICAL IGNITION HARNESS DESCRIPTION MAG Ignition Coil Wire PTO Ignition Coil Wire Tree Clip (Into PVT Duct) Tree Clip (Into Intake Manifold) Tree Clip (Into Valve Cover) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 252 Zip Tie (Around both wiring bundles) Trunk Harness Connector Tree Clip (Trunk Harness Connector into Intake Manifold) Reverse Beeper Connector (INTL Only) Zip Tie (Wrap around both wiring bundles) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 253 CPS In-line Connector Retention Clip (Into Coolant Hose Bracket) Crankshaft Position Sensor Retention Clip (Into Transmission) Gear Position Sensor Connector Speed Sensor Connector Tree Clip (Into Transmission Bracket) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 254: Electronic Control Unit (Ecu)
If a problem is encountered, and you (load), engine coolant temperature, crankshaft position determine the ECU to be faulty, contact the Polaris and engine speed (RPM), throttle pedal position and Service Department for specific handling instructions. Do battery voltage.
Page 255: Ecu Replacement
ECU. NOTICE Upon removing the ECU connector, you should hear a “click” when the connector is fully open. 6. Remove the ECU from the vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 256: Crankshaft Position Sensor (Cps)
Inspect CPS and flywheel encoder ring for damage. Refer to CPS REPLACEMENT procedure. 5. If the resistance is incorrect, follow the CPS REPLACEMENT procedure. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.10 © Copyright Polaris Inc.
Page 257: Cps Replacement
CPS Retaining Fastener: 9 ft-lbs (12 Nm) 7. Route CPS wire lead through wire clip reconnect CPS harness connector NOTICE Make sure CPS harness connector standoff remains properly secured. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.11 © Copyright Polaris Inc.
Page 258: Electronic Throttle Control (Etc)
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 259: Starter System Service
• 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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.13 © Copyright Polaris Inc.
Page 260: Starter Solenoid Bench Test
/ stud. 4. Remove the starter mounting fasteners. 5. Pull starter motor towards the driver's side to disengage it from the engine, and remove from the vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.14 © Copyright Polaris Inc.
Page 261 5. Install the Intake Manifold. Refer to Intake Manifold specification. Service page 3.16. 6. Connect the battery. Refer to Battery Service page 2.62. TORQUE Starter Mounting Fasteners: 7 lb-ft (10 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.15 © Copyright Polaris Inc.
Page 263: Voltage Drop Test
Starter Motor Turns - Engine Does Not Rotate • Faulty starter drive • Faulty starter drive gears or starter motor gear • Faulty flywheel gear or loose flywheel 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.17 © Copyright Polaris Inc.
Page 265 INSTALLATION 1. Mounting the ignition coil on the chassis and install the two fasteners . Torque to specification. TORQUE Ignition Coil Retaining Fastener: 6 ft-lbs (8 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.19 © Copyright Polaris Inc.
Page 266: Spark Plug
• Inspect the ground electrode for signs of wear or irregular engine conditions. Verify the electrode gap is correct. 2. Remove the MAG spark plug wire and PTO spark plug wire 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.20 © Copyright Polaris Inc.
Page 267 4.20 to ensure they are fit for service. TORQUE Spark Plug: 15 ft-lbs (20 Nm) 2. Install the MAG spark plug wire and PTO spark plug wire 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.21 © Copyright Polaris Inc.
Page 268: Ignition System Testing
Primary 0.4 Ω Between 2 & 3 Secondary Between High Tension 6.794k Ω ± (PTO) Lead Caps Secondary Between High Tension 7.239k Ω ± (MAG) Lead Caps 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.22 © Copyright Polaris Inc.
Page 269: Temp / Manifold Absolute Pressure Sensor (T-Map)
The T-MAP sensor is a non-serviceable item. If it is faulty, it must be replaced. IMPORTANT This sensor should only be tested using the Digital Wrench® Diagnostic Software (dealer only). 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.23 © Copyright Polaris Inc.
Page 270: Engine Coolant Temperature Sensor (Ect)
Ensure no leaks are present at the fuel line to rail 3. Remove the fuel line from fuel rail. Refer to Fuel Line connection. Quick Connect Removal page 5.6. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.24 © Copyright Polaris Inc.
Page 271: Ect Resistance Values
0.140 kΩ 0.148 kΩ 248 (120) 0.113 kΩ 0.109 kΩ 0.116 kΩ 266 (130) 0.086 kΩ 0.086 kΩ 0.093 kΩ 284 (140) 0.071 kΩ 0.068 kΩ 0.074 kΩ 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.25 © Copyright Polaris Inc.
Page 272: Ect Sensor Test
'ON' while the engine is running. Refer to COOLANT TEMPERATURE SENSOR for additional ECT sensor information. Polaris dealers can test the sensor by using Digital Wrench® Diagnostic Software (dealer only). ECT SENSOR RESISTANCE READINGS TEMPERATURE °F (°C)
Page 273: Oxygen Sensor
INSTALLATION 1. Apply anti-seize to the O2 sensor threads. IMPORTANT Only apply anti-seize to the sensor threads. Do NOT apply anti-seize to the O2 sensor bulb. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.27 © Copyright Polaris Inc.
Page 274: Oxygen Sensor Diagnostic Tips
• The Air/Fuel Ratio reading in Digital Wrench will indicate what action the ECU has taken to reach 14.7:1 Stoichiometric. – An O2 sensor reading of 0.78V indicates a rich engine condition, therefore the ECU commands the injector pulse width lean. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.28 © Copyright Polaris Inc.
Page 275 WIRE COLOR PIN AND WIRE CONNECTION Gray Sensor Ground Sensor Output Black White Heater Power White Heater Ground MEASUREMENT O2 Sensor Heater Resistance: 15.8 Ω - 18.6 Ω 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.29 © Copyright Polaris Inc.
Page 276: Drive Mode Switch
2. Reinstall the switch by pushing straight in until the switch detents engage on the dash panel. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.30 © Copyright Polaris Inc.
Page 277: Accelerator Position Sensor (Aps)
The APS is calibrated to the throttle pedal. If the APS is faulty, the throttle pedal assembly must be replaced. 1. Disconnect the APS harness 2. Remove the three fasteners retaining the throttle pedal bracket to the chassis. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.31 © Copyright Polaris Inc.
Page 279: Fan Control Circuit Operation / Testing
4. If the fan runs with the sensor harness disconnected, but will not turn on when the engine is hot, check the coolant temperature sensor and connector terminals. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 4.33 © Copyright Polaris Inc.
Page 282: General Information - Fuel System
• Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system. Dirt, even in small quantities, can cause significant problems. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 283: Electronic Fuel Injection
• Fuel Rail / Supply Line • Ignition Coil • Intake Plenum • Accelerator Position Sensor (APS) • Temp / Manifold Absolute Pressure Sensor (T-MAP) • Wire Harness Assembly 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 284: Fuel System Component Locations
- Located on the intake plenum, on top of the fuel injectors. 3. Fuel Supply Line - Connected to the left end of the fuel rail and top of the fuel pump. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 285: Fuel Lines
• The fuel line is routed from the fuel tank to the fuel rail on the engine. It is secured to the engine breather hose, inner clutch cover and clutch duct with retention clips. NOTICE Image is from top looking down. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 286: Fuel Line Quick Connect Removal
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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 287 3. Broken retaining tabs, or any sign of cracks in the retaining clip. The retaining clip is responsible for holding the quick connect on the line when under fuel pressure. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 288: Fuel Supply Line Service
2. To remove the fuel line from the tank or the fuel rail , pull open tabs while moving the connector out to release the line. Refer to Fuel Line Quick Connect Removal page 5.6 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 290: Fuel Vent Line Routing
The fuel tank is vented through a vent line. The vent line is routed from the fuel tank underneath the driver seat and secured into a vertical section of the frame with a vent line termination fitting. NOTICE Image orientation is from the front driver-side of the vehicle 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.10 © Copyright Polaris Inc.
Page 291: Fuel Vent Line Routing (Evap Models)
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 Purge Valve Purge Jumper Line Purge Line Routing Clip Fresh Air Lines 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.11 © Copyright Polaris Inc.
Page 292: Fuel Tank
Fuel Tank Asm Tank Vent / Rollover Valve Fuel Inlet Fuel Pump / Regulator Fuel Level Float Arm Fuel Cap Gasket Preliminary Fuel Filter Fuel Sender Nut 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.12 © Copyright Polaris Inc.
Page 293: Fuel Tank Service
A small amount of fuel may come out of the fuel lines or pump fitting. Properly drain fuel into a suitable container. 6. Remove the fuel tank vent line quick connect fitting from the tank. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.13 © Copyright Polaris Inc.
Page 294 11. Rotate and slide the fuel tank and remove the tank from vehicle. TORQUE Seat Base Fastener: 10 ft-lbs (14 Nm) 3. Connect the three plastic ties to retain the main wire harness to the fuel tank. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.14 © Copyright Polaris Inc.
Page 295 Service page 11.41. 7. Connect the fuel tank vent line quick connect fitting 11. Connect the battery. Refer to Battery Service page to the tank fitting. 2.62. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.15 © Copyright Polaris Inc.
Page 296: Fuel Pump
• 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 page 5.19 procedure. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.16 © Copyright Polaris Inc.
Page 297: Fuel Pressure Test
7 volts is present. NOTICE If the voltage was below 7 VDC, test the battery, ignition switch, relay(s), wiring harness and ECU. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.17 © Copyright Polaris Inc.
Page 298 11. If the pump still does not operate, check for correct ECU operation by plugging in a known-good ECU of the same model. 12. If the pump still does not operate, replace the fuel pump assembly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.18 © Copyright Polaris Inc.
Page 299: Fuel Pump Replacement
A small amount of fuel may come out of the fuel lines or pump fitting. Properly drain fuel into a suitable container. 6. Disconnect the fuel pump electrical harness 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.19 © Copyright Polaris Inc.
Page 300 15. Gently push down on fuel pump flange ensuring flange is centered. 9. Transfer old fuel pump to a suitable container capable of safely holding fuel. Fuel pump will retain some fuel. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.20 © Copyright Polaris Inc.
Page 301 Use care when starting nut, ensuring threads are properly aligned. Verify orientation marks are still aligned between fuel pump and fuel tank. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.21 © Copyright Polaris Inc.
Page 302: Evap System
3. Connect the vent line , purge line and fresh air line 4. Install the driver’s rocker panel. Refer to Rocker Panel Service page 11.41. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.22 © Copyright Polaris Inc.
Page 303: Purge Valve Service
When reinstalling, ensure the electrical connector is fully seated and the quick connect lines are fully latched and seated. Gently pull back on the lines to confirm. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.23 © Copyright Polaris Inc.
Page 304: Fuel Injector
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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.24 © Copyright Polaris Inc.
Page 305: Fuel Injector Test
MAG harness lead to the MAG injector to ensure proper engine operation. The MAG wire colors are Red/Blue and Black; the PTO wire colors are Red/Blue and White. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.25 © Copyright Polaris Inc.
Page 306 7. Carefully pull the injector(s) off of the fuel rail as needed. CAUTION Use care not to damage the fuel injector O-rings during installation. TORQUE Fuel Rail Fasteners: 5 ft-lbs (7 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.26 © Copyright Polaris Inc.
Page 307 4. Connect the fuel supply line and ensure the latch is pushed down. Gently pull back to ensure it is fully seated. 5. Connect the battery. Refer to Battery Service page 2.62. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 5.27 © Copyright Polaris Inc.
Page 310: General Information - Pvt System
DRIVEN SPRING (PN) ALTITUDE 0-1800 Meters 32-112 HC Black Black (0-6000 Feet) (1323704) (7045195) (7044761) 1800-3700 Meters 32–102 HC Black Black (6000 - 12000 Feet) (1323713) (7045195) (7044761) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 311: Pvt System Overview
Rather than vary throttle position, as a conventional governor does, the PVT system changes engine load requirements by either upshifting or backshifting. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 312: Drive Belt
3. Remove the belt off the bottom of the driven clutch and slowly turn the driven clutch counter-clockwise to aid in removal. 3. Install the outer clutch cover. PVT Clutch Cover Service page 6.7. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 313: Driven Clutch Alignment
Step 3: 96 ft-lbs (130 Nm) splines and shaft are clean and free of debris. 10. Reinstall the drive belt and outer cover assembly. Refer to Drive Belt Service page 6.4. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 314: Pvt System Service
44 in-lbs (5 Nm) Outer Clutch Cover Fastener Outer Clutch Cover Seal Inner Clutch Cover Intake Duct Drain 72-78 in-lbs (8-9 Intake Duct Hose Fastening Nut: M6 x 1.0 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 315: Pvt Clutch Cover Service
REMOVAL 1. Remove the eight fasteners securing the clutch cover to the vehicle. 2. Lift the cover over the a-arm assembly. 3. Rotate the cover towards the engine. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 316 Torque the fasteners to 3. Install the cover in the vehicle and rotate counter specification. clockwise. TORQUE Clutch Cover Fasteners: 44 in-lbs (5 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 317: Drive Clutch Removal / Installation
Stationary Sheave is necessary, the Drive Clutch puller will need to be used. Remove the outer slip fit post in order to insert the Drive Clutch holding tool. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 318: Driven Clutch Removal / Installation
96 ft-lbs (130 Nm) Drive Clutch Retaining Bolt (Stationary sheave completely removed): Step 1: 110 ft-lbs (149 Nm) Step 2: Loosen Fastener Step 3: 96 ft-lbs (130 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.10 © Copyright Polaris Inc.
Page 319: Inner Pvt Cover Service
A-arm. 4. Install all driven clutch washers , belleville washer and the bolt. Torque to specification. TORQUE Driven Clutch Bolt: 20 ft-lbs (27 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.11 © Copyright Polaris Inc.
Page 320 PVT Air Duct Clamp: 35 in-lbs (4 Nm) 4. Connect the three retention clips to secure the chassis harness and fuel line to the inner clutch cover. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.12 © Copyright Polaris Inc.
Page 321 7. Install the driven clutch. Refer to Driven Clutch Removal / Installation page 6.10. 8. Install the outer clutch cover. Refer to PVT Clutch Cover Service page 6.7. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.13 © Copyright Polaris Inc.
Page 322: Drive Clutch Service
Drive Clutch Cover Fasteners: M6 x 1.0 x 50 Drive Clutch Cover Outer Clutch Post O-ring Drive Clutch Spring Belleville Washer Washer Clutch Spider Movable Sheave Spacer Thrust Washers Bearing Stationary Sheave 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.14 © Copyright Polaris Inc.
Page 323: Drive Clutch Service
Position 3 jaw puller in the positions shown 2. Remove cover bolts evenly in a cross pattern and remove cover plate 5. Perform Drive Clutch Inspection. Refer to Drive Clutch Inspection page 6.17. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.15 © Copyright Polaris Inc.
Page 324 1. Install the clutch spider assembly. cross pattern to specification. 2. Install the washer , belleville washer and clutch spring IMPORTANT Belleville washer must be installed with dome facing the outer post. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.16 © Copyright Polaris Inc.
Page 325: Drive Clutch Inspection
A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. Inspect all rollers before reassembly. MEASUREMENT Button to Tower Clearance: 000-.010” 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.17 © Copyright Polaris Inc.
Page 326 • Verify there are no binding or rough spots. If problems are noted, replace the bearing and thrust washers. MEASUREMENT Shaft Diameter: 1.57 in (39.98 mm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.18 © Copyright Polaris Inc.
Page 328: Bushing Service
Lift sheave off puller. 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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.20 © Copyright Polaris Inc.
Page 329 (PN 5020634) into center of clutch cover. 4. Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.21 © Copyright Polaris Inc.
Page 330: Driven Clutch Service
Stationary Sheave 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 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.22 © Copyright Polaris Inc.
Page 331: Driven Clutch Service
4. Remove spring cap and clutch spring from the helix Universal Clutch Compressor: PU-50518–A IMPORTANT Mark Helix to Sheave hole orientation before removing helix. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.23 © Copyright Polaris Inc.
Page 332 . Ensure the clutch spring is fully seated. 6. Inspect the sheaves for excessive wear or damage. Replace if necessary. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.24 © Copyright Polaris Inc.
Page 333: Helix And Movable Sheave Bushing Inspection
5. Torque the three T50 torx fasteners specification. TORQUE Driven Clutch Helix Fasteners: 32 ft-lbs (44 Nm) 6. Once back together, verify the alignment marks made during disassembly are properly aligned. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.25 © Copyright Polaris Inc.
Page 334: Bushing Service
2. From the bottom of the Helix, insert the new bushing and bushing adapter (PN 5020636) 3. Install the main adapter , spacer adapter, and securing nut on top of the Helix. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.26 © Copyright Polaris Inc.
Page 335: Vehicle Creeping
Does than Roller, Pin, when you put it vehicle? vehicle come to a and Thrust into gear? stop? Washer Inspection. ↓ ↓ ↓ Greater than 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.27 © Copyright Polaris Inc.
Page 336 Inspection and button rides assembly necessary. freely? Bushing Service. smoothly in and helix tower. Replace drive clutch. ↓ If problem persists, replace the drive clutch. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 6.28 © Copyright Polaris Inc.
Page 338: General Information - Transmission
41 oz (1200 mL) Fluid Capacity 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 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 339: Shift Cable
6. Remove both bushings from the shift lever and service as needed. 7. Perform the previous steps in reverse order to reinstall the shift lever (lever, cable, dash panel, shift knob). 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 340: Shift Cable Adjustment
• AWD light displayed on instrument cluster • Ratcheting noise on deceleration • Inability to engage into a gear • Excessive gear lash (noise) • Gear selector moving out of desired range 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 341 5. Loosen the lower jam nut and pull the cable out of the mount bracket to move the upper jam nut 7. Reinstall the cable in the bracket. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 342 10. Reinstall the rubber bezel. 11. With the engine off, check the following: • Shifter fully engages all gears. • Dash is not moving when shifting into Park/High 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 343: Shift Cable Routing
TRANSMISSION SHIFT CABLE ROUTING NOTICE Ensure the retention points and the jam nuts are secure. TOP VIEW 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 345: Shift Cable Service
4. Remove the 10mm fastener , two push rivets and T40 Torx fastener securing the left dash bracket. 8. Remove the propshaft tunnel cover. Refer to Floor Panel Service page 11.63. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 346 15. Loosen the locknut securing the shift cable to the vehicle battery. transmission bracket. Retain bracket for reassembly. 12. Remove the 10mm fastener securing the shift cable to the transmission. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.10 © Copyright Polaris Inc.
Page 348 Shift Cable Fastening Nut: 13 ft-lbs (18 Nm) 10. Install the left dash bracket by rotating in as shown. TORQUE Shift Cable Locknut: 13 ft-lbs (18 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.12 © Copyright Polaris Inc.
Page 349 T40 Dash Bracket Fastener: 42 in-lbs (5 Nm) 12. Install the center dash panel and connect all electrical connectors. IMPORTANT Ensure the top retaining tabs are engaged in the dash. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.13 © Copyright Polaris Inc.
Page 350: Transmission Service
28 ft-lbs (38 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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.14 © Copyright Polaris Inc.
Page 351: Transmission Vent Line Routing
The transmission vent line runs along the rear passenger side frame. It is secured along the front frame by one retention clip as shown. The vent line ends its routing secured into a vertical section of the frame with a vent line termination fitting. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.15 © Copyright Polaris Inc.
Page 352: Transmission Removal And Installation
8. Remove the engine to transmission mounting fasteners and washers on the PTO side of the engine. 11. Lift the transmission straight up to remove from the vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.16 © Copyright Polaris Inc.
Page 353 Transmission Rear Isolator Fastener: 40 ft-lbs (54 Nm) IMPORTANT Do NOT torque at this time. 3. Loosen the two fasteners securing the transmission mount bracket to the engine. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.17 © Copyright Polaris Inc.
Page 354 9. Torque the engine to transmission mounting fasteners and washers on the MAG side of the engine. TORQUE Mounting Fasteners: 45 ft-lbs (61 Nm) TORQUE Rear Engine Mount Fasteners: 5 ft-lbs (7 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.18 © Copyright Polaris Inc.
Page 355 14. Install the transmission vent line. Refer to Transmission Vent Line Routing page 7.15. 15. Connect the shift cable from the transmission. Refer to Shift Cable Service page 7.9. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.19 © Copyright Polaris Inc.
Page 356: Transmission Disassembly
CAUTION Do not pry on the transmission case mating surfaces or the transmission cases will be damaged and leak oil after it is reassembled. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.20 © Copyright Polaris Inc.
Page 358 4. If necessary, disassemble the other end of the reverse shaft. Remove the bearing , Park/Low shift dog, retaining ring, washer, low gear and needle bearing from the reverse shaft. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.22 © Copyright Polaris Inc.
Page 359: Differential Operation
TURF mode is only available in drive gears and when the shaft through or damage to the gear teeth may the parking brake is released (INTL models). occur. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.23 © Copyright Polaris Inc.
Page 361 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 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.25 © Copyright Polaris Inc.
Page 362: Bevel Differential Disassembly
2. Remove eight fasteners retaining the ring gear. 6. Remove output gear and Thrust washer 3. Remove ring gear , thrust washer , and output gear 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.26 © Copyright Polaris Inc.
Page 363: Bevel Differential Assembly
When installing the ring gear, align with the mark made of the carrier during disassembly. NOTICE Align the hole of the differential pin with the dowel pin hole in the carrier. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.27 © Copyright Polaris Inc.
Page 365: Gear, Shaft, Bearing Inspection
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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.29 © Copyright Polaris Inc.
Page 366: Snorkel Gear Backlash Procedure
NOTICE 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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.30 © Copyright Polaris Inc.
Page 367 Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 8. Apply Loctite® 242 to the threads of the bearing cover retaining screws. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.31 © Copyright Polaris Inc.
Page 368: Transmission Assembly
17. Torque the locking screw to specification. TORQUE Snorkel Locking Screw: 9 ft-lbs (12 Nm) TORQUE Shift Fork Screws: 9 ft-lbs (12 Nm) 3. Slide engagement dog onto retaining pins of shift fork. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.32 © Copyright Polaris Inc.
Page 369 Bearing Engagement Dog Retaining Ring Washer Low Gear (67T) Needle Bearing Reverse Shaft Gear (48T) Engagement Dog Gear (49T) Bearing Washer Bearing Chain Input Shaft Bearing 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.33 © Copyright Polaris Inc.
Page 371 If using NEW left hand gearcase, holes are "not Retaining Clip threaded" for self tapping screws to form threads. Washer 13. Install new seals into the transmission case halves. Torsion Spring Drum 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.35 © Copyright Polaris Inc.
Page 372 17. Install the detent pawl onto the shift shaft and carefully install the compression spring IMPORTANT Make sure the transmission is in HIGH gear prior to reassembly 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.36 © Copyright Polaris Inc.
Page 373 23. Install the bellcrank onto the shift shaft. Note the key splined on the bellcrank and shift shaft. Install the nut and torque to specification. 24. Refer to Transmission Installation page complete the repair. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 7.37 © Copyright Polaris Inc.
Page 377: General Information - Final Drive
PART DESCRIPTION SPECIFICATION Front Gearcase Coil 22 - 24.3 Ω Resistance Front Gearcase Oil 2021+: 9.3 oz. (275 mL) Capacity 2021+ Non-EPS: 3.82:1 Drive Ratio 2021+ EPS: 3.25:1 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 378: Rear Hub Identification
(PN 7557134). TORQUE TORQUE Rear Wheel Hub Castle Nut: Rear Wheel Hub Castle Nut: Aluminum Hub – 110 ft-lbs (149 N·m) Iron Hub – 180 ft-lbs (244 N·m) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 379: Front Bearing Carrier Service
6. Remove the washer(s) from the front wheel hub assembly. CAUTION Do not hang caliper by the brake line. Use wire to hang caliper to prevent damage to brake line. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 380 11. Using a soft faced hammer, lightly tap the bearing carrier while removing the upper and lower ball joints ends from the bearing carrier. 12. Pull the bearing carrier out to remove it from the driveshaft. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 381: Bearing Replacement
1. Thoroughly clean the front bearing carrier housing and the outer race on the new bearing. Be sure that all oil residue has been removed from each surface. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 382: Bearing Carrier Installation
3. Install the lower ball joint fastener. Torque to specification. TORQUE Tie Rod End Fastener: 40 lb-ft (54 Nm) 6. Apply grease to the drive shaft splines. TORQUE Lower Ball Joint fastener: 42 lb-ft (57 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 384 13. 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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.10 © Copyright Polaris Inc.
Page 385: Prop Shaft Service
3. Install the front gearcase. Refer to Front Gearcase Installation page 8.26. INSTALLATION 1. Carefully guide the propshaft through the right front of the vehicle and align with the transmission input shaft. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.11 © Copyright Polaris Inc.
Page 386: Front Prop Shaft Service (Crew)
Before removing the propshaft, make and index mark on the shaft on the carrier and differential side so that the shaft can be reinstalled in the same orientation. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.12 © Copyright Polaris Inc.
Page 387 7. Slide the propshaft off the rear splines and carefully guide the prop shaft out from the right front of the vehicle. 3. Rotate the prop shaft onto the front differential and align the pin hole. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.13 © Copyright Polaris Inc.
Page 388: Rear Prop Shaft Service (Crew)
5. Install the skid plate. Refer to Skid Plate Service page 11.35. 6. Install the front bumper. Refer to Front Bumper Service page 11.31 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.14 © Copyright Polaris Inc.
Page 389 TORQUE Center Bearing Fasteners: 40 ft-lbs (54 Nm) 3. Install the front prop shaft. Refer to Front Prop Shaft Service (CREW) page 8.12. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.15 © Copyright Polaris Inc.
Page 390: Propshaft U-Joint Service
ID than the U-joint cap OD on one end. 5. Tighten clamp with hand tools to force U-joint cups out of yoke. 6. Discard and replace all U-joint parts that were removed from the yoke. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.16 © Copyright Polaris Inc.
Page 391: Propshaft U-Joint Assembly
8. Tighten clamp until both caps are flush with yoke and one cap is past retaining ring groove 4. Place caps into yoke bores and align with U-joint ends by hand. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.17 © Copyright Polaris Inc.
Page 392 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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.18 © Copyright Polaris Inc.
Page 393: Front Gearcase Service 2020 Models
AWD Coil 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 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.19 © Copyright Polaris Inc.
Page 394: Front Gearcase Removal
AWD coil pigtail. 5. Remove the bolts retaining the front gearcase to the skid plate frame. 6. Remove the vent hose from the front gearcase. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.20 © Copyright Polaris Inc.
Page 395: Front Gearcase Disassembly / Inspection
NOTICE Nylon spacer is non-serviceable and should not be removed. 4. Remove and inspect the armature plate . Refer to AWD DIAGNOSIS for detailed inspection process. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.21 © Copyright Polaris Inc.
Page 396 9. Inspect the pinion gear for chipped, broken or missing teeth. Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.22 © Copyright Polaris Inc.
Page 397 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.23 © Copyright Polaris Inc.
Page 398: Front Gearcase Assembly
6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 4. Install the RH output hub into the gearcase housing. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.24 © Copyright Polaris Inc.
Page 399 11. Install a new O-ring on the cover plate assembly. NOTICE Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.25 © Copyright Polaris Inc.
Page 400: Front Gearcase Installation
4. Install new gearcase mounting bolts and torque to specification. TORQUE Front Gearcase Mounting Bolts: 30 ft-lbs (41 Nm) TORQUE Front Gearcase Cover Plate Screws: 9 ft-lbs (12 N·m) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.26 © Copyright Polaris Inc.
Page 401 7. Add the proper lubricant to the front gearcase. Check drain plug for proper torque. Refer to Maintenance Chapter for fluid fill and change information. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.27 © Copyright Polaris Inc.
Page 402: Front Gearcase Service 2021+ Models
Bushing (Inner) Cage Spacer Bearing Armature Plate Bearing Snap Ring (Inner) Roller Cage Assy. Bushing Snap Ring (Outer) H-Clip Magnetic Plug (Drain) Pinion Seal 10 ft-lbs (14 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.28 © Copyright Polaris Inc.
Page 403: Front Gearcase Removal
5. Remove both tie rod ends from the bearing carriers. 8. Remove both front axles from the front gearcase. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.29 © Copyright Polaris Inc.
Page 404 12. Remove the upper front gearcase nut and bolt. 13. Remove the lower front gearcase nut and bolt. 14. Slide the propshaft off the splines of the front gearcase. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.30 © Copyright Polaris Inc.
Page 405: Front Gearcase Disassembly (Non-Adc)
2. Remove cover fasteners and remove the cover plate Nylon spacer is non-serviceable and should not be assembly. removed. 4. Remove and inspect the armature plate. Refer to AWD DIAGNOSIS for detailed inspection process. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.31 © Copyright Polaris Inc.
Page 406 6. Remove the ring gear and roll cage assembly from the gearcase housing. With the ring gear removed 9. Remove pinion seal. inspect the ring gear dowel pin and ensure that it is seated correctly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.32 © Copyright Polaris Inc.
Page 407 10. Remove the internal retaining ring / snap ring. 11. Remove the pinion gear assembly from the gearcase housing. 12. Inspect and clean the gearcase housing and replace any oil seals and O-rings upon assembly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.33 © Copyright Polaris Inc.
Page 408: Front Gearcase Inspection
1. Inspect the pinion gear for chipped, broken or missing teeth. NOTICE Refer to the “Electronic Parts Catalog” for individual part availability. Most parts are to be replaced as an assembly or as a complete kit. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.34 © Copyright Polaris Inc.
Page 409 OUTPUT HUB / BEARING INSPECTION 1. Inspect both output hub assemblies. Inspect the bearings and replace if needed. Bearing Inner Bushing / Spacer Hub Assembly Outer Bushing / Spacer 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.35 © Copyright Polaris Inc.
Page 410: Front Gearcase Assembly (Non-Adc)
NOTICE 5. Install inner and outer bushing / spacer. If bearing replacement was required, press new bearing onto the pinion shaft and install a new snap ring. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.36 © Copyright Polaris Inc.
Page 412 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 N·m) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.38 © Copyright Polaris Inc.
Page 413: Front Gearcase Installation
Prop Shaft Pinch Bolt Fastener: 22 ft-lbs (30 N·m) 6. Install the vent line on the gearcase and ensure it’s routed properly. 7. Connect the AWD harness. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.39 © Copyright Polaris Inc.
Page 414 11. Install both tie rod ends from the bearing carriers. Torque to specification. TORQUE Tie Rod Retaining Nut: Step 1: 30 ft-lbs (41 Nm)Step 2: Tighten additional 90° 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.40 © Copyright Polaris Inc.
Page 415 / fill plug for proper torque. Refer to Maintenance Chapter for fluid fill and change information. TORQUE Front Gearcase Fill / Drain Plug: 10 ft-lbs (14 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.41 © Copyright Polaris Inc.
Page 416: Front Gearcase Vent Line Routing
The vent line ends its routing secured into a horizontal section of the frame with a vent line termination fitting. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.42 © Copyright Polaris Inc.
Page 418: All Wheel Drive (Awd) Diagnosis
A minimum of 11 volts DC should be present. 3. If electrical tests are within specification, remove gearcase (see FRONT GEARCASE REMOVAL) and inspect components. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.44 © Copyright Polaris Inc.
Page 419 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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.45 © Copyright Polaris Inc.
Page 420: Rear Bearing Carrier Service
CAUTION Do not hang the caliper by the brake line. Use mechanics wire to hang the caliper to prevent possible damage to the brake line. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.46 © Copyright Polaris Inc.
Page 421: Rear Bearing Carrier Bearing Replacement
Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. 3. Inspect bearing carrier housing for scratches, wear or damage. Replace rear bearing carrier if damaged. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.47 © Copyright Polaris Inc.
Page 422: Rear Bearing Carrier Installation
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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.48 © Copyright Polaris Inc.
Page 423 10. Install the wheel, washers and wheel nuts. Torque wheel nuts to specification. TORQUE Wheel Nuts (Steel): 60 lb-ft (81 Nm) Wheel Nuts (Alum): 120 lb-ft (163 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.49 © Copyright Polaris Inc.
Page 424: Rear Drive Shaft Service
CAUTION Do not hang the caliper by the brake line. Use mechanics wire to hang the caliper to prevent possible damage to the brake line. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.50 © Copyright Polaris Inc.
Page 425: Rear Drive Shaft Installation
Apply an anti-seize compound to the splines of both ends of the shaft. 10. Tilt the carrier down while removing the end of the driveshaft. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.51 © Copyright Polaris Inc.
Page 426 4. Rotate the bearing carrier onto the drive axle and rotate into upper A-arm. 5. Install the upper bearing carrier fastener. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.52 © Copyright Polaris Inc.
Page 427 Refer to text for grease capacity of CV joints and CV joint boots. 3. Clean the grease from the face of the joint. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.53 © Copyright Polaris Inc.
Page 428 The amount of grease provided in the boot kit is pre- If the grease in the joint is obviously contaminated with measured. Use entire contents of package. water and/or dirt, the joint should be replaced. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.54 © Copyright Polaris Inc.
Page 429 CV Boot Clamp Pliers: 8700226 18. Install and tighten the large clamp using the appropriate clamp tool. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.55 © Copyright Polaris Inc.
Page 431 CV Boot Clamp Pliers: 8700226 NOTICE The amount of grease provided in the boot kit is pre- measured. Use entire contents of package. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.57 © Copyright Polaris Inc.
Page 432 21. Position the boot lip in its groove. Install and tighten the large clamp using the appropriate clamp tool. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 8.58 © Copyright Polaris Inc.
Page 434: General Information - Steering / Suspension
10.0 in (25.4 IMPORTANT Suspension Travel New ball joint bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 435: Steering & Suspension Assembly Views
Step 1: 30 ft-lbs Power Steering Unit Frame (41 Nm) Tie Rod Retaining Nut Step 2: Tighten additional 90° Power Steering Unit Frame 14 ft-lbs (19 Nm) Fasteners 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 436: Front Suspension Assembly View
Lower Ball Joint Upper Ball Joint Fastener: M10 x 1.25 x 60 42 ft-lbs (57 Nm) Steering Knuckle Upper Ball Joint Nut: M10 x 1.25 42 ft-lbs (57 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 437 40 ft-lbs (54 Nm) Lower Shock Mounting Nut: M10 x 1.25 40 ft-lbs (54 Nm) Shock Assembly Upper Shock Mounting Nut: M10 x 1.25 40 ft-lbs (54 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 438: Rear Suspension Assembly View
17 ft-lbs (23 Nm) Stabilizer Bar Link Fastener Stabilizer Bar Mounting Nut: M8 x 1.25 31 ft-lbs (42 Nm) Shock Mounting Fastener: M10 x 1.25 x 60 40 ft-lbs (54 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 439: Steering Assembly Service
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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 440: Steering Rack Removal
Torque to specification. 3. Remove the three fasteners retaining the steering rack to the frame. TORQUE Steering Rack Mounting Nuts: 40 ft-lbs (54 Nm) 4. Remove Steering Rack from vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 441 Step 1: 30 ft-lbs (41 Nm)Step 2: Tighten additional DESCRIPTION TORQUE 90° Steering Wheel Cap 5. Perform Wheel Toe Adjustment. 65 ft-lbs (88 Nm) Steering Wheel Hub Insert Bushing Steering Shaft, Upper Tilt Assembly 9850045 R01 - 2020-2021 RANGER 1000 Service Manual © Copyright Polaris Inc.
Page 442: Power Steering Unit Installation
65 ft-lbs (88 Nm) ®. 13. Wipe the pivot tube clean of any excess Loctite 14. Install steering wheel cap and field test steering operation. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.10 © Copyright Polaris Inc.
Page 443: Steering Inspection
WARNING TORQUE Due to the critical nature of the procedures outlined in Steering Wheel Tilt Assembly Fasteners: this chapter, Polaris recommends steering component 40 ft-lbs (54 Nm) repair and adjustment be performed by an authorized Polaris MSD certified technician. 10. Reconnect both electrical harnesses onto the power steering unit.
Page 444: Tie Rod End / Wheel Hub Inspection
• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut). 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.12 © Copyright Polaris Inc.
Page 445: Wheel Toe Adjustment
Damage may not be immediately apparent if done incorrectly. 4. After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 13 ft-lbs (18 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.13 © Copyright Polaris Inc.
Page 446: Front A-Arm Service
30 ft-lbs (40 N·m) + 180° from the bearing carrier. Front Ball Joint Nut: 45 ft-lbs (61 Nm) WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.14 © Copyright Polaris Inc.
Page 447: A-Arm Bushing Replacement
2. Install new Pivot Cap , Bushings , and Pivot Shaft into new A-arm. A light press force may be needed.. CAUTION Do not damage brake line during this process 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.15 © Copyright Polaris Inc.
Page 448 The locking agent on the existing bolts was destroyed during removal. DO NOT reuse old hardware. Serious injury or death could result if fasteners come loose during operation. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.16 © Copyright Polaris Inc.
Page 449: Ball Joint Service
A-arm to gain enough clearance to install ball joint tool (PU-50506) on the upper ball joint. To service the lower ball joint: 6. Remove and discard the lower ball joint pinch bolt. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.17 © Copyright Polaris Inc.
Page 450: Ball Joint Installation
4. Install the Press Asm. onto the A-arm to engage the Installation Adapter and Spacer. 5. Tighten the Press Asm. screw and fully install the ball joint into the arm. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.18 © Copyright Polaris Inc.
Page 451 Wheel Nuts (Steel): 60 lb-ft (81 Nm) Image for reference only. Wheel Nuts (Aluminum): 120 lb-ft (163 Nm) 7. Repeat the ball joint service procedure for any additional A-arm ball joint replacements. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.19 © Copyright Polaris Inc.
Page 452: Rear A-Arm Service
A-arm. 8. Using a 15 mm socket and open-end wrench, remove the two fasteners retaining the upper A-arm to the frame. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.20 © Copyright Polaris Inc.
Page 453: Rear Upper A-Arm Installation
WARNING TORQUE Upon A-arm installation completion, test vehicle at low Rear Upper A-Arm to Bearing Carrier Fastener: speeds before putting into service. 44 ft-lbs (60 N·m) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.21 © Copyright Polaris Inc.
Page 454: A-Arm Bushing Replacement
A-arm. A light press force may be needed.. 6. Remove the fastener retaining the lower A-arm to the bearing carrier and frame. 7. Remove the lower A-arm from the vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.22 © Copyright Polaris Inc.
Page 455: Rear Lower A-Arm Installation
31 ft-lbs (42 Nm) 120 ft-lbs (163 Nm) Stabilizer Bar Link Fasteners: 17 ft-lbs (23 Nm) WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.23 © Copyright Polaris Inc.
Page 456: Shock / Spring Service
(weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock. MISTING OR WEEPAGE LEAKAGE 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.24 © Copyright Polaris Inc.
Page 457: Shock Removal And Installation
Ensure the vehicle is properly supported before beginning this procedure. Severe injury or death can occur if the vehicle tips or falls. 2. Remove the upper shock mounting bolt and nut. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.25 © Copyright Polaris Inc.
Page 458: Shock Spring Replacement
5. Turn adjustment cam to set preload distance noted in Step 1. 6. Reinstall shock onto vehicle and torque new fasteners to specification. TORQUE Lower Shock Mounting Fastener: 40 ft-lbs (54 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 9.26 © Copyright Polaris Inc.
Page 460: General Information - Brake System
MAX LEVEL line! • Make sure caliper moves freely on guide pins (where When servicing Polaris brake systems use only Polaris applicable). DOT 4 Brake Fluid (PN 2872189). • Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.
Page 461: Brake System Specifications
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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.3 © Copyright Polaris Inc.
Page 462: Brake System Service
CALIPER, BRAKE - REAR RH CALIPER, BRAKE - REAR LH LINE, BRAKE - REAR LH FITTING, CROSS CYLINDER, BRAKE MASTER LINE, BRAKE - FRONT LH CALIPER, BRAKE LH SCRAPER 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.4 © Copyright Polaris Inc.
Page 464 BRAKE SYSTEM REAR BRAKE LINE FROM MASTER CYLINDER TO JUNCTION BLOCK REAR BRAKE LINES FROM JUNCTION BLOCK TO REAR CALIPERS 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.6 © Copyright Polaris Inc.
Page 465: Brake Line Clocking
BRAKE LINE CLOCKING MASTER CYLINDER ITEM DESCRIPTION ANGLE To Tee Block 30° +/- 2.5° To Right Front Caliper 25° +/- 2.5° To Left Front Caliper 15° +/- 2.5° 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.7 © Copyright Polaris Inc.
Page 468: Brake Fluid Replacement / Brake Bleeding
This procedure should be used to change fluid or bleed brakes during regular maintenance. CAUTION Always wear safety glasses. Polaris DOT 4 Brake Fluid P/N: 2872189 CAUTION 5. Begin bleeding procedure with caliper furthest from Brake fluid will damage finished surfaces.
Page 469 1/2" (1.3 cm). 16. Check brake system for fluid leaks. 17. Verify fluid level is filled between “MIN” and “MAX” level after procedure is completed. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.11 © Copyright Polaris Inc.
Page 470: Master Cylinder Service
3. Remove master cylinder and place a fluid catch container under the master cylinder brake lines. CAUTION Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.12 © Copyright Polaris Inc.
Page 471: Master Cylinder Installation
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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.13 © Copyright Polaris Inc.
Page 472: Front Brake Pad Service
FRONT BRAKE PAD INSPECTION line. Support caliper to avoid kinking or bending brake line. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.14 © Copyright Polaris Inc.
Page 473: Front Brake Pad Installation
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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.15 © Copyright Polaris Inc.
Page 474: Brake Burnishing Procedure
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) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.16 © Copyright Polaris Inc.
Page 475: Front Caliper Service
FRONT CALIPER ASSEMBLY VIEW 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 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.17 © Copyright Polaris Inc.
Page 476: Front Caliper Removal
4. Place a container below the caliper to catch brake fluid when removing line. Remove brake line from caliper. 5. Loosen brake pad adjustment set screw to allow brake pad removal after the caliper is removed. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.18 © Copyright Polaris Inc.
Page 477: Front Caliper Disassembly
Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. NOTICE Be sure to clean the seal grooves in caliper body. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.19 © Copyright Polaris Inc.
Page 478: Front Caliper Inspection
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 479: Front Caliper Installation
Ensure the brake line is clocked properly. Refer to installation. Brake Line Clocking page 10.7. NOTICE If new brake pads are installed, brake burnishing is TORQUE recommended. Brake Line Banjo Bolts: 15 ft-lbs (20 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.21 © Copyright Polaris Inc.
Page 480: Rear Brake Pad Service
4. Remove caliper mounting bolts and lift caliper off of disc. NOTICE When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.22 © Copyright Polaris Inc.
Page 481: Rear Brake Pad Inspection
Install pads with friction material facing each other. WARNING If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new clean pads. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.23 © Copyright Polaris Inc.
Page 482: Rear Caliper Service
REAR CALIPER ASSEMBLY VIEW PART DESCRIPTION PART DESCRIPTION Brake Pad Assembly Brake Piston Caliper Mount Assembly Ring Brake Caliper Bolt Pin Seal Boot Bleeder Screw Pin Bushing Boot Plug Cap 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.24 © Copyright Polaris Inc.
Page 483: Rear Caliper Removal
7. Clean the brake disc, caliper body and caliper pistons with brake cleaner or alcohol. 5. If necessary, loosen brake pad adjustment set screw 2-3 turns to allow brake pad removal after the caliper is removed. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.25 © Copyright Polaris Inc.
Page 484: Rear Caliper Disassembly
5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTICE 3. Inspect the brake disc and pads as outlined in this chapter. Be sure to clean caliper body seal grooves. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.26 © Copyright Polaris Inc.
Page 485: Rear Caliper Assembly
Clean the disc and pads with brake parts cleaner or 60 ft-lbs (81 Nm) denatured alcohol to remove any dirt, oil or grease. Wheel Lug Nuts (Aluminum): 120 ft-lbs (163 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.27 © Copyright Polaris Inc.
Page 486: Brake Disc Service
MEASUREMENT Brake Disc Thickness Standard: 0.188" ( 4.78 mm) Service Limit: 0.170" (4.32 mm) MEASUREMENT Brake Disc Thickness Variance Service Limit: 0.002” (0.051 mm) difference between measurements 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.28 © Copyright Polaris Inc.
Page 487: Disc Runout
TORQUE Front Brake Disc Mounting Bolts: 18 ft-lbs (24 Nm) Rear Brake Disc Mounting Bolts: 28 lb-ft (38 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.29 © Copyright Polaris Inc.
Page 488 Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 10.30 © Copyright Polaris Inc.
Page 491: General Information - Body / Frame
WARNING Serious injury may result if machine tips or falls. Be sure machine is secure before beginning any procedure that requires machine lifting. Always wear eye protection. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.3 © Copyright Polaris Inc.
Page 492: Body Assembly Views
10 ft-lbs (14 Nm) Seat Frame Fastener: M8 x 1.25 x 20 Engine Shield Rear A-arm Bracket 14 ft-lbs (19 Nm) Crossbar Fastener: M8 x 1.25 x 55 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.4 © Copyright Polaris Inc.
Page 493: Chassis Assembly View (Crew)
Main Frame Front A-arm Bracket 10 ft-lbs (14 Nm) Seat Frame Fastener: M8 x 1.25 x 20 14 ft-lbs (19 Nm) Cross Bar Fastener Rear A-arm Bracket 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.5 © Copyright Polaris Inc.
Page 494: Rops Assembly View
Cab Frame- Front Right Windshield Plate Fastener 36 ft-lbs (49 Nm) Seat Back Screw 18 inch-lbs (2 Nm) Seat Belt Fastener 40 ft-lbs (54 Nm) Rubber Washer 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.6 © Copyright Polaris Inc.
Page 495 BODY / FRAME DESCRIPTION TORQUE Bolster Handle Nut 6 ft-lbs (8 Nm) Closeout Panel Fastener 42 in-lbs (5 Nm) Heat Shield Fastener 42 in-lbs (5 Nm) Heat Shield Washer 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.7 © Copyright Polaris Inc.
Page 496: Rops Assembly View (Crew)
SCR-HXFL-M12X1.75X90 10.9 ZPC NUT-HEX-M8X1.25 10 P&O NUT-HXFL M12X1.75 8 ZOD NYL 45 ft-lbs (61 N·m) SCR-HXFL-M8X1.25X20 8.8 ZOD P3 6 ft-lbs (8 Nm) WELD-BOLSTER, LH, M WELD-BOLSTER, RH, M 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.8 © Copyright Polaris Inc.
Page 497 WELD-BOLSTER, FRONT, RH, M SCR-HXFLSH-M12X1.75–M14X9 40 ft-lbs (54 Nm) WASHER-SEATBELT, RUBBER BOLT-M8X1.25X20, HXFLG 10 ft-lbs (14 Nm) NUT-HXFL-M10X1.5 8 ZB3 NYL 36 ft-lbs (49 Nm) PLATE-WINDSHIELD MNT, UPR, 17 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.9 © Copyright Polaris Inc.
Page 498: Dash Panel Assembly View
42 in-lbs (5 Nm) Dash Fastener: M6 x 1.0 x 25 22 in-lbs (2.5 Nm) Lower Dash Panel Screw: 14 x 3/4 Center Dash Trim Lower Dash Panel 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.10 © Copyright Polaris Inc.
Page 499: Front Body Assembly View
Front Fascia Hood Push Rivet Right Front Fender Right Front Fender Flare Under Hood Liner 42 in-lbs (5 Nm) Hood Liner Fastener: M6 x 1.0 x 20 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.11 © Copyright Polaris Inc.
Page 500: Floors And Bulkhead Assembly View
Push Rivet 22 in-lbs (2.5 Nm) Floor Screw: 14 x 3/4 Prop Shaft Tunnel Rocker Panel Intake Cover 22 in-lbs (2.5 Nm) Intake Cover Screw: 14 x 3/4 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.12 © Copyright Polaris Inc.
Page 501 A-Pillar Seal Side Roof Seal Rear Roof Seal 42 in-lbs (5 Nm) Roof Bracket Fastener: M6 x 1.0 x 15 Driver Roof Bracket Passenger Roof Bracket Roof Panel 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.13 © Copyright Polaris Inc.
Page 502: Roof Assembly View
24 in-lbs (3 Nm) Roof Fastener: Driver Roof Bracket 42 in-lbs (5 Nm) Roof Bracket Fastener: M6 x 1.0 x 15 Passenger Roof Bracket Rear Roof Seal Rear Roof Panel 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.14 © Copyright Polaris Inc.
Page 503: Rear Panel Assembly View
REAR GLASS FASTENER 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 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.15 © Copyright Polaris Inc.
Page 504: Cargo Box Assembly View
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 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.16 © Copyright Polaris Inc.
Page 505 TAILGATE LATCH FASTENER 7 ft lbs (9 Nm) TAILGATE LATCH TAILGATE LATCH FASTENER NUT 7 ft lbs (9 Nm) TAILGATE SUPPORT FASTENER M6x1.0 42 in-lbs (5 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.17 © Copyright Polaris Inc.
Page 506 14 ft lbs (19 Nm) CARGO BOX FRAME FASTENING NUT 14 ft lbs (19 Nm) CARGO BOX SUPPORT FRAME CARGO BOX LATCH HANDLE BOX BUMPER CARGO BOX HEAT SHIELD 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.18 © Copyright Polaris Inc.
Page 507: Cab Frame Service
3. Connect the wiper motor connectors , and install the trim panel with rear view mirror. 3. Release the lock-and-ride connections securing the windshield to the ROPS. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.19 © Copyright Polaris Inc.
Page 508: Tip-Out Windshield Service
3. With the aid of an assistant, remove the windshield from the vehicle. INSTALLATION 1. With the aid of an assistant, install the windshield on the vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.20 © Copyright Polaris Inc.
Page 509: Tip-Out Windshield Adjustment
NOTICE Do not remove screws. 3. Align the windshield seal with the notch in the center of the upper dash panel. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.21 © Copyright Polaris Inc.
Page 510: Roof Service
2. Remove the two T27 Torx fasteners retaining the front of the roof panel. TORQUE Tip-out Windshield Hinge Fasteners: 17 ft-lbs (23 Nm) 6. Rotate the windshield clockwise to secure to the vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.22 © Copyright Polaris Inc.
Page 511 5. With the aid of an assistant, lift the roof straight up to remove. 3. If necessary, install the rear roof seal , and align with mounting holes. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.23 © Copyright Polaris Inc.
Page 512 9. If equipped, install the headliner. Refer to Headliner Service page 11.25. 10. If equipped, install the audio unit.. 11. If equipped, install any electrical harnesses attached to the roof. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.24 © Copyright Polaris Inc.
Page 513: Headliner Service
2. Remove the five push rivets securing both headliners to the windshield plate. 4. Remove the two T30 fasteners from the front headliner. 5. Remove the front headliner. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.25 © Copyright Polaris Inc.
Page 514 2. Install the two T30 fasteners from the front headliner. Torque to specification. TORQUE 24 in-lbs (3 N·m) 3. Install the rear headliner and tuck behind the ROPS on both sides. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.26 © Copyright Polaris Inc.
Page 515 6. Remove the five push rivets securing both front headliners to the windshield plate. 3. Remove the four T40 Torx fasteners securing the rear headliner to the roof. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.27 © Copyright Polaris Inc.
Page 516 8. Remove the two T30 fasteners from the front headliner. 3. Install the five push rivets to secure both headliners to the windshield plate. 9. Lower the front headliner. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.28 © Copyright Polaris Inc.
Page 517 9. Install the three fasteners retaining the front of the rear headliner to the roof. Torque to specification. TORQUE Rear Headliner Fasteners: 42 in-lbs (5 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.29 © Copyright Polaris Inc.
Page 518 42 in-lbs (5 Nm) 11. Torque the two T25 fasteners and washers retaining the center of the headliner to the roof. TORQUE T25 Rear Headliner Fasteners: 24 in-lbs (3 N·m) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.30 © Copyright Polaris Inc.
Page 519: Exterior Body Service
3. Loosely install the two fasteners retaining the bottom of the bumper to the frame. 3. Carefully pull the bumper straight out to remove it from the vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.31 © Copyright Polaris Inc.
Page 520: Front Fender Service
2. Remove the three push rivets and the T-30 torx fastener 3. Remove the two push rivets behind the front fascia. 4. Pull upper fender straight out as shown. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.32 © Copyright Polaris Inc.
Page 521 22 in lbs (3 Nm) 4. Install the hood by inserting into slots and locking 2. Install the two push rivets behind the front fascia. down with 1/4 turn fasteners. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.33 © Copyright Polaris Inc.
Page 522 3. Remove the five T-40 torx fasteners TORQUE 4. Pull the lower fender straight out from vehicle to remove. Body Fastener 42 in-lbs (5 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.34 © Copyright Polaris Inc.
Page 523: Skid Plate Service
• Remove the thirteen fasteners and washers securing the skid plate to the vehicle and remove the skid plate. 4. Reinstall the upper fender. TORQUE Skid Plate Fasteners: 6 ft-lbs (8 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.35 © Copyright Polaris Inc.
Page 524: Front Fascia Service
3. Remove the two T-40 torx fasteners fastener holes. NOTICE Front Bumper removed for clarity. 4. Disconnect the headlight connector. Remove the three T-25 torx fasteners . Remove the headlight assembly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.36 © Copyright Polaris Inc.
Page 525 42 in-lbs (5 Nm) 5. Perform Headlight Adjustment. Refer to 6. Install the upper fender. Refer to Front Fender Service page 11.32. TORQUE Body Fasteners 42 in-lbs (5 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.37 © Copyright Polaris Inc.
Page 526: Side Bezel Cover Service
2. Carefully pry out the retainers and remove the cover towards the front of the vehicle. INSTALLATION 1. Install the intake cover and ensure the front retention clips are properly seated. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.38 © Copyright Polaris Inc.
Page 527: Side Bezel Service
7. Pivot the side bezel outward and lift up to remove from the vehicle. 4. Remove the inside push rivet securing the side bezel to the rocker panel. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.39 © Copyright Polaris Inc.
Page 528 2. Carefully pull the intake duct retainers in to secure the intake duct.. TORQUE Bolster Fasteners: 3. Install the two rear side bezel push rivets. 6 ft-lbs (8 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.40 © Copyright Polaris Inc.
Page 529: Rocker Panel Service
4. DRIVER’S SIDE ONLY Remove the fuel cap. CAUTION Cover the fuel filler neck with a clean shop rag to prevent debris from entering the fuel tank. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.41 © Copyright Polaris Inc.
Page 530 Rocker Panel Fasteners: 42 in-lbs (5 Nm) 2. DRIVER’S SIDE ONLY: Install the fuel cap. 5. Install the side bezel. Refer to Side Bezel Cover Service page 11.38. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.42 © Copyright Polaris Inc.
Page 531: Rear Close-Off Panel Service
ROPS assembly. 4. After all push rivets are installed torque the Lower Rear Close-Off Panel Fasteners. TORQUE Rear Close Off Panel Fasteners: 42 in-lbs (5 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.43 © Copyright Polaris Inc.
Page 532 BODY / FRAME 5. Install the (5) heat shield retaining fasteners Torque the heat shield fasteners. TORQUE Heat Shield Fasteners: 42 in-lbs (5 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.44 © Copyright Polaris Inc.
Page 533: Decal Replacement
3. If air bubbles are found, press firmly with a clean finger or squeegee to work the bubble out from the center of the decal to the outside edges. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.45 © Copyright Polaris Inc.
Page 535 • Poor adhesion resulting in the decal coming off, allowing debris or water to reside behind it. • Screened ink of the decal lifting from the surface, which stems from an unsupported peel. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.47 © Copyright Polaris Inc.
Page 536: Cargo Box
. Remove the box shock from the cargo box. CAUTION Cargo box can drop backwards after shock is removed. Ensure the cargo box is properly supported. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.48 © Copyright Polaris Inc.
Page 537 3. With the aid of an assistant, install the box shock and cotter pin CAUTION Ensure the cargo box is properly supported when installing box shock. The box is unstable without the box shock. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.49 © Copyright Polaris Inc.
Page 538: Door Service
6. Remove the nine push rivets retaining the door panels to the door assembly. 3. Remove the fastener securing the door panel trim to the door assembly. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.50 © Copyright Polaris Inc.
Page 539 INSTALLATION 4. Install the door seal 1. Install the lower trim panel straight down over the door handle to install in the vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.51 © Copyright Polaris Inc.
Page 540 Door Panel Trim Fastener: Door Handle Fastener: 42 in-lbs (5 Nm) 42 in-lbs (5 Nm) 6. Install the crank handle and u-clip to secure the crank handle to the door. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.52 © Copyright Polaris Inc.
Page 541: Door Latch Service
4. Remove the five fasteners securing the upper TORQUE regulator support bracket, and remove the bracket. Door Latch Fasteners 8 ft-lbs (11 Nm) 2. Install the door panel. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.53 © Copyright Polaris Inc.
Page 542 3. Rotate the regulator assembly counter-clockwise while installing straight down and align with mounting holes. 7. Loosen the fasteners securing the glass to the regulator to service the glass or regulator. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.54 © Copyright Polaris Inc.
Page 543 Window Regulator Fastener: 8 ft-lbs (11 Nm) TORQUE TORQUE Window Regulator Support Fastener: Window Motor Fastener: 6 ft-lbs (8 Nm) Torque until fully seated 8. Install the door panels. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.55 © Copyright Polaris Inc.
Page 544: Door Removal / Installation
DOOR REMOVAL / INSTALLATION 1. Open the door and lift straight off the hinge. 2. Reinstall by gently installing the door over both hinges. Ensure proper door alignment. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.56 © Copyright Polaris Inc.
Page 545: Interior Body Service
4. Open the glovebox and remove the two push rivets inside. 7. Remove the remaining seven push rivets securing the dash panel to the vehicle. Lift straight up to remove the panel. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.57 © Copyright Polaris Inc.
Page 546 5. Install the two glovebox push rivets. 2. WINTER PREP MODELS: Install the six upper dash panel ducts and secure to the ducting hoses before securing the dash panel. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.58 © Copyright Polaris Inc.
Page 547: Lower Dash Panel Service
7. Install the instrument cluster. Refer to Instrument Cluster Service page 12.23. 8. Install the front fenders. Refer to Front Fender Service page 11.32. 4. Remove the two fasteners behind the center trim panel. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.59 © Copyright Polaris Inc.
Page 548 7. WINTER PREP MODELS: Cut the zip ties securing the two lower dash panel ducts before removing the dash panel. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.60 © Copyright Polaris Inc.
Page 549 42 in-lbs (5 Nm) 5. Install the center trim panel and engage the upper retainers. Plug in all electrical connectors and rotate to align the lower rivet holes. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.61 © Copyright Polaris Inc.
Page 550: Seat Back Service
3. Install the Rear Close-Off Panel. Refer to Rear Close- Off Panel Service page 11.43 4. Install the ECU. Refer to ECU Replacement page 5. Install the Cargo Box. Refer to Cargo Box Installation page 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.62 © Copyright Polaris Inc.
Page 551: Lower Seat Base Removal
2. Remove the five push rivets and eleven fasteners to remove the floor panel. NOTICE Driver’s side shown, passenger side is identical to driver’s. TORQUE Floor Fastener: 42 in-lbs (5 Nm) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.63 © Copyright Polaris Inc.
Page 552: Roof Removal / Installation
4. Pull the rear of the roof out firmly and lift it up. Slide the roof forward and off the vehicle. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.64 © Copyright Polaris Inc.
Page 553: Rear Panel Removal / Installation
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 554: Accessory Service
BODY / FRAME ACCESSORY SERVICE • Refer to accessory kit instructions for accessory removal and installation. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 11.66 © Copyright Polaris Inc.
Page 557: General Information - Electrical System
Disconnect it from the wiring harness or power • Starter Solenoid* supply. • Relays* • Fuses* • Digital Wrench ® Diagnostic Connector* • Speed Key Accessory (if installed) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.3 © Copyright Polaris Inc.
Page 558: Body Electrical Specifications
47 VAC ± 25% RPM) Stator Leg Voltage (5000 79 VAC ± 25% RPM) Starter Solenoid Terminal 2.5 Ω ± 20% Resistance (77 °F) Parking Brake Switch Normally Open 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.4 © Copyright Polaris Inc.
Page 559: Fuse Box / Circuit Protection
Power Out Power In Spare 10A Fuse Power Out Coil High Power In Cab Heater Relay Power Out Coil Low Coil High Access Relay Power In Power Out 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.5 © Copyright Polaris Inc.
Page 560 Coil Low Power In Lights 15A Fuse Power Out Power In Chassis 20 A Fuse Power Out Coil High Power In Chassis Relay Power Out Coil Low 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.6 © Copyright Polaris Inc.
Page 561: Relay Operation
R/S B+ Accessory Relay EFI RELAY provides power to the following systems: • Fuel Injectors • Ignition Coil • Fan Relay • Fuel Pump Relay • Brake Pressure Switch 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.7 © Copyright Polaris Inc.
Page 562 30-Amp fuse protected 12 Vdc constant battery voltage. Relay coil ground. Brown 12 Vdc power input from key Orange switch to enable relay. Provides 12 Vdc power for EPS Orange operation. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.8 © Copyright Polaris Inc.
Page 563: Vehicle Harness Service
Engine harness routing is located in the Engine Electrical Chapter. Refer to Engine Harness Routing page 4.3. FRONT UPPER VEHICLE ROUTING DESCRIPTION Terminal Block Terminal Block Connector Terminal Block Power Cable Left Headlight Connector Front Ground Connection Right Headlight Connector 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.9 © Copyright Polaris Inc.
Page 564 Cooling Fan Connector AWD Hub Coil Connector Brake Pressure Switch Connector Voltage Regulator Connector (AC) Voltage Regulator Connector (DC) Voltage Regulator Connector (AC) Voltage Regulator Connector (DC) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.10 © Copyright Polaris Inc.
Page 565 LEFT DASH ROUTING DESCRIPTION Tree Clip (Into Dash Brackets) EPS Signal Connector EPS Power Connector Retention Clip (Into Dash Bracket) Ignition Switch Connector Headlight Switch Connector Instrument Cluster Connector 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.11 © Copyright Polaris Inc.
Page 566 Pedal Position Sensor Connector Winch Connector In-Line Rear Accessory Switch Connector Box Lift Harness Connector Temperature Control Connector 12V Receptacle Connections Blower Motor Control AWD Switch Connector 12V Receptacle Connections 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.12 © Copyright Polaris Inc.
Page 567 CHASSIS / BODY ELECTRICAL FLOOR TUNNEL ROUTING DESCRIPTION Seat Belt Switch Connector Tree Clip (Into Trim Panel) Harness Guide Tunnel Harness Retention Covers 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.13 © Copyright Polaris Inc.
Page 568 Retention Cap Tree (Into Seat Frame) Diagnostic Connector Cooling Fan 20A Circuit Breaker Positive Battery Cable Connection Seat Belt Switch Connector Retention Clip Tree Negative Battery Cable Connection Ground Connection 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.14 © Copyright Polaris Inc.
Page 569 Retention Clip (Into Cargo Box Frame) Retention Clip (Into Bottom of Cargo Box) Retention Clip Tree (Into Vehicle Frame) Cargo Box Harness Connector (Tree Clip Into Intake Manifold) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.15 © Copyright Polaris Inc.
Page 570: Chassis Harness Removal
8. Install the front fascia. Refer to Front Fascia Service. 9. Install the upper and lower fenders. Refer to Front Fender Service page 11.32. 10. Verify proper vehicle operation. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.16 © Copyright Polaris Inc.
Page 571: Switches / Controls Service
B and C. • Turn the ignition key to START. There should be continuity between switch pins B and C; A and D. LOCATION 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.17 © Copyright Polaris Inc.
Page 572: Transmission (Gear Position) Switch
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 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.18 © Copyright Polaris Inc.
Page 573: Brake Pedal Switch Inspection
• The AWD system must be grounded to operate. DIAGNOSING SYSTEM FAILURES 1. Verify AWD switch is functional and that a minimum of 11 volts is present at the hub coil. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.19 © Copyright Polaris Inc.
Page 574: Vehicle Speed Sensor Service
Verify all wires and wiring connections have been tested properly with a known good volt/ohm meter before suspecting a component failure. 80% of all electrical issues are caused by bad/failed connections and grounds. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.20 © Copyright Polaris Inc.
Page 575: Speed Sensor Testing
• 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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.21 © Copyright Polaris Inc.
Page 576: Differential Solenoid Replacement
3. To install, reverse the removal procedure. Torque the solenoid fastener to specification. TORQUE Differential Solenoid Nut: 25 ft-lbs (34 N·m) 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.22 © Copyright Polaris Inc.
Page 577: Instrument Cluster Service
When re-installing, ensure the connectors and instrument cluster seal fully seated. FUNCTION CAN High CAN Low Switched Power (Vdc) Constant Power (Vdc) Ground High Beam Input Fuel Level Sensor 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.23 © Copyright Polaris Inc.
Page 578: Charging System Service
1. Disconnect the battery. Refer to Battery Service page 2.62 2. Remove the Crankshaft Position Sensor. Refer to CPS Replacement page 4.11. 3. Disconnect the stator connector. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.24 © Copyright Polaris Inc.
Page 580: Regulator / Rectifier Replacement
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: 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.26 © Copyright Polaris Inc.
Page 582: Charging System Troubleshooting Charging System "Break Even" Test
Y1 to Ground, Y2 to Ground, Y3 to 8. Repeat test, observing ammeter and tachometer. Ground. With lights on, charging should occur at or below 2000 RPM. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.28 © Copyright Polaris Inc.
Page 583: Regulator Testing (900 Watt)
AC VOLTAGE (VAC) RPM READING volt, replace the suspect regulator. READING 1300 21 VAC ± 25 % 3000 49 VAC ± 25 % 5000 80 VAC ± 25 % 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.29 © Copyright Polaris Inc.
Page 584: Battery Service
3. Charge the battery as recommended. BATTERY TERMINAL BLOCK The terminal block is located under the hood. The terminal block provides easy hookup for accessories. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.30 © Copyright Polaris Inc.
Page 585: Battery Off Season Storage
• Non removable cap(s) on top of battery • Distilled water or electrolyte NEVER added NOTICE Battery charge can be maintained by using a Polaris battery tender charger or by charging once a month to make up for normal self-discharge. Battery tenders can...
Page 586: Lead Acid Conventional Battery Inspection
NEVER put the sealing cap back onto the battery. The gas pressure can cause the battery to rupture. Polaris recommends using a BatteryMINDer® 1510- 1.5 AMP charger (or a similar charger), which can be ordered through your normal parts channel.
Page 587: Lead Acid Conventional Battery Maintenance
Store the battery in the vehicle with the cables disconnected, or store the battery in a cool / dry location. Batteries will self discharge more rapidly when stored in extreme temperatures. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.33 © Copyright Polaris Inc.
Page 588 6. Press down evenly to break the foil seals and allow electrolyte to flow into the battery. NOTICE Air bubbles will begin to rise, indicating the flow of electrolytes. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.34 © Copyright Polaris Inc.
Page 589: Dry Shipped Agm Battery Charging And Testing
12.5V, charge it immediately, or the battery runs the risk of sulfation. To charge a Dry Shipped AGM battery, do the following: 1. Charge the battery for 1 hour using the Polaris recommended charger. IMPORTANT Reference the recommended charging information on the battery decal.
Page 590: Dry Shipped Agm Battery Maintenance
/ dry location. Continue to maintain the battery with the BatteryMINDer® 2012 AGM - 2 AMP charger and inspect the battery every 60 days. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.36 © Copyright Polaris Inc.
Page 591: Lead Acid Low Maintenance Battery
CHARGING AND TESTING If the battery is stored or used in a partially charged Polaris recommends using a BatteryMINDer® 1510- 1.5 condition, hard crystal sulfation will form on the plates, AMP charger (or a similar charger), which can be ordered reducing the efficiency and service life of the battery.
Page 592: Agm Low Maintenance Battery
The battery will self-discharge when CHARGING disconnected from a vehicle, and will discharge at a Polaris recommends using the BatteryMINDer® 2012 faster rate when connected. If the battery voltage falls AGM - 2 AMP battery charger to charge and maintain below 12.5V, it should be charged immediately using the...
Page 593: Agm Battery Charging - Deeply Discharged (Below 3 Volts)
BATTERY CHARGING BATTERY CHARGING TIME CAPACITY RATE 2 amps 4011496 11 hours 18 AH 2 amps 4014770 8 hours 12 AH 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.39 © Copyright Polaris Inc.
Page 594: Agm Low Maintenance Battery Maintenance
If you do not drive the vehicle for more than TWO weeks, Authorized Polaris dealers / distributors are required to maintain the Absorbent Glass Mat (AGM) battery with the use the conductance analyzer when testing 12V Polaris BatteryMINDer®...
Page 595: Battery Open Circuit Voltage Test (Ocv)
9.5 volts during the test, replace the battery. 75% Charged 12.50V 12.80V 50% Charged 12.20V 12.50V 25% Charged 12.0V 12.20V 0% Charged less than 11.9V less than 12.0V 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.41 © Copyright Polaris Inc.
Page 596: Battery Specific Gravity Test
20 hrs NOTICE Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.42 © Copyright Polaris Inc.
Page 597: Electronic Power Steering (Eps)
EPS system is detected, the system will illuminate a fault indicator and transition to a normal mechanically coupled steering system. The system is Polaris Digital Wrench® compatible for simplified diagnostics and system troubleshooting through the vehicle’s diagnostic port.
Page 598: Lighting System Service
• Move the switch to OFF. There should be continuity between switch pins 1 and 2; 5 and 7. NOTICE Pins 9 and 10 provide power and ground to light the switch lamp. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.44 © Copyright Polaris Inc.
Page 599: Headlight Adjustment
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. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.45 © Copyright Polaris Inc.
Page 601: Headlight Bulb Replacement
6. Install the harness onto the new headlight bulb and install the hood. 3. Connect the harness to the bulb. 4. Adjust headlights. See . 5. Install the front fenders. See Front Fender Service page 11.32. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.47 © Copyright Polaris Inc.
Page 602: Tail Light Service
12 volts and that a ground path is present. 4. Install the new LED lamp assembly by reversing this procedure. 5. Test the tail light / brake light after installation to verify proper function. 9850045 R01 - 2020-2021 RANGER 1000 Service Manual 12.48 © Copyright Polaris Inc.
Page 603 Front Body ............11.11 Brake Line Clocking Body Assembly View Front Brake Caliper..........10.8 Roof Assembly View .......... 11.13 Master Cylinder............10.7 Roof Assembly View (CREW) ......11.14 Rear Brake Caliper ..........10.9 9850045 R01 - 2020-2021 RANGER 1000 Service Manual IX.1 © Copyright Polaris Inc.
Page 604 Stator Inspection ..........12.24 Differential Solenoid Chassis Harness Routing Circuit Operation ..........12.21 Below Seat Routing ..........12.14 Overview ............12.21 Cargo Box Routing ..........12.15 Digital Wrench 9850045 R01 - 2020-2021 RANGER 1000 Service Manual IX.2 © Copyright Polaris Inc.
Page 605 Electrical Maintenance Feature Map............1.43 Chassis / Engine Electrical Ground ......2.64 Guided Diagnostics ..........1.40 Throttle Pedal Inspection .........2.64 Polaris Mobile Digital Wrench® (PMDW) .....1.45 Electronic Power Steering (EPS) Serial Number Location ...........1.42 Operation ............12.43 Software Installation and Updates ......1.41 Troubleshooting - EPS Non-Functional MIL Off .....1.70 Troubleshooting - EPS Non-Functional MIL On .....1.69...
Page 606 Front Bearing Carrier Removal / Inspection ....8.5 Fuel Pump Front Gearcase Assembly ........ 8.24, 8.36 Fuel Sender Test ............5.16 Front Gearcase Assembly View......8.19, 8.28 Operation Overview ..........5.16 Front Gearcase Disassembly ........8.31 Replacement............5.19 9850045 R01 - 2020-2021 RANGER 1000 Service Manual IX.4 © Copyright Polaris Inc.
Page 607 Instrument Cluster Prop Shaft Pinouts .............. 12.23 Front Prop Shaft Service (CREW) ......8.12 Rear Prop Shaft Service (CREW) ......8.14 Instrument Cluster Service Prop Shaft Service Installation ............12.23 9850045 R01 - 2020-2021 RANGER 1000 Service Manual IX.5 © Copyright Polaris Inc.
Page 608 Rear Drive Shaft Digital Wrench® .............1.40 Installation ............8.51 Transmission............7.2 Removal...............8.50 Website..............1.6 Rear Panel Specifications Assembly View ............ 11.15 Cooling System............3.76 Removal / Installation ..........11.65 Speed Sensor 9850045 R01 - 2020-2021 RANGER 1000 Service Manual IX.6 © Copyright Polaris Inc.
Page 609 Upper Dash Panel Service Spring Pre-Load Adjustment ........2.57 Switch Installation ............11.58 AWD / 2WD / TURF ..........12.19 Removal............. 11.57 Gear Position ............12.18 Headlamp............12.44 Ignition............... 12.17 9850045 R01 - 2020-2021 RANGER 1000 Service Manual IX.7 © Copyright Polaris Inc.
Page 610 Vent Line Termination Fitting ........... 5.9 Vent Line Routing Front Gearcase............8.42 Transmission............7.15 VIN ................1.18 Location ...............1.18 VIN Number .............1.18 Voltage Drop Test ............4.17 Wiring Diagrams ............49 9850045 R01 - 2020-2021 RANGER 1000 Service Manual IX.8 © Copyright Polaris Inc.

This manual is also suitable for:

Ranger 1000 2021

Polaris RANGER 1000 2020 Service Manual

Chapter 1 1 General Information

Maintenance Chapter 2 Maintenance 2

Chapter 3 Engine / Cooling / Exhaust

Chapter 4 Engine Electrical

Chapter 5 Fuel System

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Polaris RANGER 1000 2020