Polaris RANGER XP 900 2013 Manual
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Polaris RANGER XP 900 2013 Manual

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2013 / 2014 RANGER XP 900 - 2014 RANGER
XP 900 / CREW 900
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed August 2013 (PN 9924880 Rev 2- 1/10/2014)
© Copyright 2013 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Summary of Contents for Polaris RANGER XP 900 2013

  • Page 1 Publication Printed August 2013 (PN 9924880 Rev 2- 1/10/2014) © Copyright 2013 Polaris Sales 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 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 3 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE CHAPTER 4: FUEL SYSTEM - GENERAL CHAPTER 5: BODY / STEERING / SUSPENSION CHAPTER 6: CLUTCHING CHAPTER 7:...

  • Page 4: Table Of Contents

    ................1.14 DECIMAL EQUIVALENTS 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 5: Vehicle Identification

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016; H = 2017 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 6: Vehicle And Engine Serial Number Locations

    GENERAL INFORMATION VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the vehicle identification number (VIN) and the engine model number and serial number. VEHICLE IDENTIFICATION NUMBER (VIN) - The VIN can be found stamped on a portion of the upper left frame rail above the airbox.

  • Page 7: Vehicle Information

    NOTE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.

  • Page 8: Special Tools

    Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris.service-solutions.com/...

  • Page 9: General Specifications

    Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 10: Detailed Specifications: 2013 - 2014 Ranger Xp 900 / Eps

    *Not in Fuse/Relay Box ECM: 20 Amp Lights: 20 Amp EPS (OPT): 30 Amp* 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 11: General Specifications: 2014 Ranger Crew 900 / Eps

    Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 12: Detailed Specifications: 2014 Ranger Crew 900 / Eps

    *Not in Fuse/Relay Box ECM: 20 Amp Lights: 20 Amp EPS (OPT): 30 Amp* 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 13: Clutch Chart

    1500-3700 Meters 27-83 Wht / Blu 7044015 (5000 - 12000 Feet) (5632754) (7044111) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 1.10 © Copyright Polaris Sales Inc.

  • Page 14: Misc. Specifications And Charts

    9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 1.11 © Copyright Polaris Sales Inc.

  • Page 15: Standard Bolt Torque Specification

    232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 1.12 © Copyright Polaris Sales Inc.

  • Page 16: Sae Tap / Drill Sizes

    2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 1.13 © Copyright Polaris Sales Inc.

  • Page 17: Decimal Equivalents

    15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 1.14 © Copyright Polaris Sales Inc.
  • Page 18 ....... 2.11 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS GENERAL VEHICLE INSPECTION AND MAINTENANCE..........2.12 .
  • Page 19 ............... . .2.40 BRAKE PAD / DISC INSPECTION 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 20: Maintenance

    Have an authorized Polaris dealer perform these Severe Use Definition services. • Frequent immersion in mud, water or sand •...

  • Page 21: Pre-Ride - 50 Hour Maintenance Interval

    Inspect for free movement; replace pedal 500 (800) Throttle Pedal 50 H assembly if needed 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 22: 50 - 500 Hour Maintenance Interval

    MAINTENANCE ▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. 50 - 500 HOUR MAINTENANCE INTERVAL MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM...

  • Page 23: Maintenance Quick Reference

    Headlight Aim Adjust as needed ▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. MAINTENANCE QUICK REFERENCE III. Frequency* Item Lube Rec.
  • Page 24 Method Maintain fluid level Check level during pre-ride between “MAX and “MIN” inspection; change fluid every Brake Fluid Polaris DOT 4 Brake Fluid lines on the master two years cylinder reservoir Front Gearcase Polaris Demand Drive Fluid Initial level check at 25 hours or Add lubricant until it is 1 month;...

  • Page 25: Grease Lubrication Points

    Grease the fitting thoroughly washing or Propshaft Yoke (3 pumps maximum) submerging the vehicle 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 26 MAINTENANCE 2013 - 2014 RANGER XP 900 Lubrication Points 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 27 MAINTENANCE 2014 RANGER CREW 900 Lubrication Points 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.10 © Copyright Polaris Sales Inc.

  • Page 28: Service Products And Lubricants

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

  • Page 29: General Vehicle Inspection And Maintenance

    4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.12 © Copyright Polaris Sales Inc.
  • Page 30 If transmission still ratchets after cable adjustment, the transmission will require service. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.13 © Copyright Polaris Sales Inc.

  • Page 31: Fuel System And Air Intake

    Replace line if necessary. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.14 © Copyright Polaris Sales Inc.

  • Page 32: Vent Line

    Refer to Chapter 4 “Pedal Position Sensor (PPS)” if experiencing a lack of throttle response. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.15 © Copyright Polaris Sales Inc.

  • Page 33: Air Filter Service

    6. Place the air filter into the airbox. Reposition the lower airbox cover and install the (5) retaining latches. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.16 © Copyright Polaris Sales Inc.

  • Page 34: Engine Air Intake Exploded View

    MAINTENANCE ENGINE AIR INTAKE EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.17 © Copyright Polaris Sales Inc.

  • Page 35: Engine

    Access the oil dipstick and oil fill cap by tilting the rear cargo box. Polaris recommends the use of PS-4 Synthetic or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil. FLUID CAPACITY Recommended Engine Oil:PS-4 Synthetic (PN 2876244)Ambient Temp Range: -35°...
  • Page 36 14. Verify the transmission is still in PARK. 15. Start the engine and allow it to idle for 30 seconds. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.19 © Copyright Polaris Sales Inc.

  • Page 37: Engine Crankcase Breather Hose Inspection

    Follow the breather hose (A) from the crankcase fitting (B) to the airbox (C). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.20 © Copyright Polaris Sales Inc.
  • Page 38 NOTE Replace rubber isolators (F) upon assembly. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.21 © Copyright Polaris Sales Inc.

  • Page 39: Exhaust - Spark Arrestor

    4. Inspect the screen for wear and damage. Replace if TORQUE needed. Valve Cover Bolts:7 ft-lbs. (10 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.22 © Copyright Polaris Sales Inc.
  • Page 40 MAINTENANCE 5. Reinstall the arrestor and torque the retaining screw to specification. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.23 © Copyright Polaris Sales Inc.

  • Page 41: Transmission And Front Gearcase

    Do not overfill. 9. Reinstall drain plug with a new O-ring and torque to specification. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.24 © Copyright Polaris Sales Inc.

  • Page 42: Front Gearcase Lubrication

    Level Check”). 7. Place a drain pan under the front gearcase drain plug. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.25 © Copyright Polaris Sales Inc.
  • Page 43 Fill / Drain Plug:8-10 ft-lbs (11-14 Nm) 13. Check for leaks. Dispose of used fluid properly. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.26 © Copyright Polaris Sales Inc.

  • Page 44: Cooling System

    Overheating of engine could occur if air is not fully purged from system. Polaris Premium 60/40 coolant is already premixed and With the engine at operating temperature, the coolant ready to use. Do not dilute with water.

  • Page 45: Cooling System Hoses

    Do not over-tighten hose clamps at radiator, or radiator fitting may distort.Radiator hose clamp torque is 36 in- lbs (4 Nm). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.28 © Copyright Polaris Sales Inc.

  • Page 46: Radiator Inspection / Cleaning

    Chapter 3. FLUID CAPACITY Recommended Coolant:Polaris Premium Pre-Mixed Antifreeze (PN 2871534) (Quart)(PN 2871323) (Gallon) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.29 © Copyright Polaris Sales Inc.

  • Page 47: Pvt / Final Drive / Wheel And Tire

    PVT system components for water damage. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.30 © Copyright Polaris Sales Inc.

  • Page 48: Drive Shaft Boot Inspection

    24.7mm to allow it to clear the rim. NOTE Do not lubricate the stud or the lug nut. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.31 © Copyright Polaris Sales Inc.

  • Page 49: Tire Inspection

    Tire Pressure Inspection (Cold) Front Rear 10 psi (69 kPa) 12 psi (83 kPa) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.32 © Copyright Polaris Sales Inc.

  • Page 50: Electrical And Ignition System

    (D). 3. Coat the terminals with dielectric grease or petroleum jelly. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.33 © Copyright Polaris Sales Inc.

  • Page 51: Chassis / Engine Electrical Ground

    4. Inspect the engine ground terminals. Be sure they are clean and tight. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.34 © Copyright Polaris Sales Inc.
  • Page 52 (B). Ensure wires are pushed down all the way so they engage onto the spark plugs. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.35 © Copyright Polaris Sales Inc.

  • Page 53: Steering

    WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component • If abnormal movement is detected, inspect the hub and repair and adjustment be performed by an authorized wheel assembly to determine the cause (loose wheel Polaris MSD certified technician.

  • Page 54: Wheel Toe Alignment Inspection

    Damage may not be immediately apparent if done incorrectly. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.37 © Copyright Polaris Sales Inc.
  • Page 55 • After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut:14 ft-lbs. (19 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.38 © Copyright Polaris Sales Inc.

  • Page 56: Suspension

    2. Remove the upper shock mounting bolts (A) from each side of the vehicle. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.39 © Copyright Polaris Sales Inc.

  • Page 57: Brake System

    6. The disc (s) should be replaced if thickness is less than the specified service limit (see Chapter 9 for specifications). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 2.40 © Copyright Polaris Sales Inc.
  • Page 58 ............. . .3.40 CYLINDER HEAD WARP INSPECTION 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 59 TROUBLESHOOTING ..................3.89 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 60 ................3.89 ENGINE / COOLING SYSTEM 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 61: General Information

    PV-1253 or PV-4019 (Quick Release) Valve Spring Compressor Adapter PV-43513-A Water Pump Mechanical Seal Installer PU-50564 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 62: Engine Lubrication Specifications

    MAG side of the engine. 4. Remove the plug (A) and insert the oil pressure adapter. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 63 6. Upon assembly, torque the crankcase gallery plug to specification. Test results are based on the use of the recommended engine oil (Polaris PS-4 or PS-4 Extreme Duty) at TORQUE operating temperature, and may vary considerably if any other oil is used or if engine is not up to Crankcase Gallery Plug:11 ft-lbs (15 Nm) temperature.

  • Page 64: Engine Oil Flow Chart

    ENGINE ENGINE OIL FLOW CHART 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 65: Engine Service Specifications

    0.001" (0.025 mm) Cylinder to Piston Clearance 0.0014" - 0.0026" (0.035 - 0.065 mm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 66 1.4939" - 1.4946" (37.946 - 37.962 mm) Balance Shaft Bearing Journal O.D. (Service Limit) 1.4921" (37.900 mm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 67: Engine Detail - Torque Values / Sequences / Assembly Notes

    ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.10 © Copyright Polaris Sales Inc.

  • Page 68: Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons

    ENGINE BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.11 © Copyright Polaris Sales Inc.

  • Page 69: Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump

    CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.12 © Copyright Polaris Sales Inc.

  • Page 70: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

    ENGINE CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.13 © Copyright Polaris Sales Inc.

  • Page 71: Spark Plugs / Starter / Thermostat Housing / Trans Joint / Valve Cover

    SPARK PLUGS / STARTER / THERMOSTAT HOUSING / TRANS JOINT / VALVE COVER 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.14 © Copyright Polaris Sales Inc.

  • Page 72: Engine Exhaust System

    Install new exhaust gaskets and torque all hardware to specification. TORQUE Headpipe Mounting Bolts:18 ft-lbs (24 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.15 © Copyright Polaris Sales Inc.

  • Page 73: Engine Cooling System

    Pressure Cap Relief 13 PSI 1. Open the front hood (see Warning under “Cooling System Pressure Test”). Polaris Premium Antifreeze2871534 - Quart2871323 - 2. Remove radiator pressure cap and test using a Gallon pressure cap tester (commercially available). 3. The radiator cap relief pressure is 13 psi. Replace Recommended Coolant cap if it does not meet this specification.

  • Page 74: Radiator Fan Removal

    RADIATOR REMOVAL / COOLANT DRAIN 1. Allow the vehicle to cool down if recently operated. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.17 © Copyright Polaris Sales Inc.

  • Page 75: Thermostat Replacement

    16. Refer to the “Cooling System Bleeding Procedure” provided in this chapter. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.18 © Copyright Polaris Sales Inc.
  • Page 76 12. Fill cooling system and proceed to “Cooling System Bleeding Procedure” provided in this chapter. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.19 © Copyright Polaris Sales Inc.

  • Page 77: Cooling System Exploded View

    ENGINE COOLING SYSTEM EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.20 © Copyright Polaris Sales Inc.

  • Page 78: Cooling System Bleeding Procedure

    10. Allow engine and cooling system to completely cool down (see CAUTION). 11. Remove the pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck. 12. Open the bleed screw to allow any trapped air to escape.

  • Page 79: Water Pump Installation

    Do not reuse the water pump O-rings. Always use NEW O-rings each time the water pump is removed. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.22 © Copyright Polaris Sales Inc.

  • Page 80: Water Pump Service

    Be sure orientation and routing are correct. 12. Install the exhaust system as outlined in this chapter. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.23 © Copyright Polaris Sales Inc.
  • Page 81 8. Inspect the water pump shaft bore for excessive wear or damage. Replace water pump housing assembly if necessary. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.24 © Copyright Polaris Sales Inc.
  • Page 82 22. Install water pump assembly into engine as shown in the “Water Pump Installation” procedure. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.25 © Copyright Polaris Sales Inc.
  • Page 83 ENGINE WATER PUMP EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.26 © Copyright Polaris Sales Inc.

  • Page 84: Engine Service

    (see Chapter 2). 4. Remove rear cargo box from vehicle (see Chapter 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.27 © Copyright Polaris Sales Inc.
  • Page 85 15. Use an overhead or portable engine hoist and suitable engine straps to secure engine in its current position. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.28 © Copyright Polaris Sales Inc.
  • Page 86 18. Remove the crankcase breather hose (Q) from the engine. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.29 © Copyright Polaris Sales Inc.

  • Page 87: Engine Installation

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.30 © Copyright Polaris Sales Inc.
  • Page 88 NOTE DO NOT torque fasteners at this time. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.31 © Copyright Polaris Sales Inc.
  • Page 89 Be sure the intake plenum runners are fully seated in the intake adapters before tightening the hose clamps. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.32 © Copyright Polaris Sales Inc.
  • Page 90 27. Install (2) new plastic tie straps to retain the harness to the transmission. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.33 © Copyright Polaris Sales Inc.

  • Page 91: Engine Mounting And Torque Values

    Ensure plug wires caps are pushed down all the way so they engage onto the spark plugs. 35. Add approximately 2.5 quarts (3.3 L) of Polaris PS-4 or PS-4 Extreme Duty Synthetic Engine Oil to the engine. Additional oil may be required after complete 29.

  • Page 92: Engine Break-In Period

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

  • Page 93: Engine Disassembly / Inspection - Top End

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.36 © Copyright Polaris Sales Inc.
  • Page 94 The crankcase has a built-in lower guide to prevent the chain from falling off the crankshaft. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.37 © Copyright Polaris Sales Inc.

  • Page 95: Camshaft Sprocket Inspection

    Service Limit: 1.4925" (37.91 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.38 © Copyright Polaris Sales Inc.
  • Page 96 Calculated Camshaft Oil Clearance: 0.0009" - 0.0028" (.022 - .072 mm) Service Limit: .0039" (.10 mm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.39 © Copyright Polaris Sales Inc.

  • Page 97: Cylinder Head Removal

    Do not touch sealing surfaces of the new head gasket. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.40 © Copyright Polaris Sales Inc.

  • Page 98: Cylinder Head Disassembly

    1. Remove all carbon from valves with a soft wire wheel or brush. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.41 © Copyright Polaris Sales Inc.
  • Page 99 Intake: 0.2155" - 0.2161" (5.475 - 5.490 mm) Exhaust: 0.2147" - 0.2153" (5.455 - 5.470 mm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.42 © Copyright Polaris Sales Inc.

  • Page 100: Combustion Chamber Cleaning

    NOTE Remove only the amount of material necessary to repair the seat surface. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.43 © Copyright Polaris Sales Inc.
  • Page 101 Look for an even and continuous contact point all the way around the valve face 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.44 © Copyright Polaris Sales Inc.
  • Page 102 8. Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.45 © Copyright Polaris Sales Inc.

  • Page 103: Engine Disassembly / Inspection - Lower End

    Chapter 10. 4. Inspect the ball bearing that supports the starter motor shaft. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.46 © Copyright Polaris Sales Inc.

  • Page 104: Water Pump Housing Removal

    Inspect the shaft and bearing surfaces in the crankcase and stator cover for excessive wear. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.47 © Copyright Polaris Sales Inc.

  • Page 105: Starter One-Way Clutch Disassembly

    9. Rotate one-way gear counterclockwise. The gear should immediately lock in position and not slip. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.48 © Copyright Polaris Sales Inc.

  • Page 106: Starter One-Way Clutch Assembly

    1. Install one-way clutch in clutch hub with flange of clutch engaged in recess. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.49 © Copyright Polaris Sales Inc.

  • Page 107: Crankcase Disassembly

    7. Remove the sump cover from the crankcase. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.50 © Copyright Polaris Sales Inc.
  • Page 108 13. Rotate the engine so the cylinder is facing up. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.51 © Copyright Polaris Sales Inc.

  • Page 109: Balance Shaft Removal / Inspection

    4. Inspect the balance shaft gear teeth for damage. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.52 © Copyright Polaris Sales Inc.

  • Page 110: Crankshaft Removal / Inspection

    8. If the crankshaft gear is damaged, the crankshaft assembly must be replaced. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.53 © Copyright Polaris Sales Inc.
  • Page 111 Main Journal 3 MAG Rod Journal Main Journal 4 Main Journal 2 PTO End 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.54 © Copyright Polaris Sales Inc.
  • Page 112 “Crankshaft Main Bearing Selection” and “Connecting Rod Bearing Selection” procedures. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.55 © Copyright Polaris Sales Inc.

  • Page 113: Crankcase Inspection

    1. Perform “ENGINE DISASSEMBLY / INSPECTION - TOP END” and the “ENGINE DISASSEMBLY / INSPECTION - LOWER END” procedures. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.56 © Copyright Polaris Sales Inc.

  • Page 114: Cylinder Inspection

    (MAG / PTO). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.57 © Copyright Polaris Sales Inc.

  • Page 115: Piston Disassembly / Inspection

    DO NOT apply heat to piston rings or a loss of radial tension could result. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.58 © Copyright Polaris Sales Inc.

  • Page 116: Piston Ring Removal

    Piston Pin O.D.: 0.7872" - 0.7874" (19.995 - 20.000 mm) Service Limit: 0.7866" (19.98 mm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.59 © Copyright Polaris Sales Inc.

  • Page 117: Piston Ring To Groove Clearance Inspection

    Always check piston ring installed gap when installing new rings and/or a new cylinder. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.60 © Copyright Polaris Sales Inc.

  • Page 118: Piston-To-Cylinder Clearance

    Step 1: 9 ft-lb (12 Nm) Step 2: 22 ft-lb (30 Nm) Step 3: Tighten add’n 90° 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.61 © Copyright Polaris Sales Inc.
  • Page 119 “Connecting Rod Bearing Selection” procedure in this chapter. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.62 © Copyright Polaris Sales Inc.

  • Page 120: Engine Assembly - Lower End

    Connecting Rod Bearing Identification Number (1 digit) Crankcase Bearing Identification Number (6 digits) Crankshaft Bearing Identification Letters (6 letters) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.63 © Copyright Polaris Sales Inc.

  • Page 121: Connecting Rod Bearing Selection

    Blue Green Blue Green Yellow Yellow bearing for Main #4 Green Yellow Yellow 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.64 © Copyright Polaris Sales Inc.

  • Page 122: Upper Crankcase Preparation

    3. Install upper rail with end gap positioned on the exhaust side of piston 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.65 © Copyright Polaris Sales Inc.

  • Page 123: Piston / Connecting Rod Assembly

    Severe engine damage may result if circlips are re-used or deformed during installation. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.66 © Copyright Polaris Sales Inc.

  • Page 124: Cylinder / Piston Installation

    Orientation arrow is also located on the bottom side of piston as an additional reference. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.67 © Copyright Polaris Sales Inc.

  • Page 125: Crankshaft Installation

    (PU-50563) onto the cylinder. The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 6. Apply Polaris PS-4 engine oil to each main and rod bearing journal of crankshaft & CRANKSHAFT INSTALLATION...

  • Page 126: Balance Shaft Installation

    MAG end gear is visible. 12. Install matching rod cap on connecting rod using markings made upon disassembly. 4. Apply Polaris PS-4 engine oil to both balance shaft journals. 13. Install new bolts and tighten evenly until snug. 14. Torque connecting rod bolts to specification...

  • Page 127: Lower Crankcase Preparation

    Press bearing inserts firmly into place. 3. Apply Polaris PS-4 engine oil to the new bearings LOWER CRANKCASE PREPARATION installed in the lower crankcase half. NOTE 4. Clean crankcase mating surfaces to remove any oil.
  • Page 128 Tighten all bolts lightly by hand. NOTE Install new M10 lower crankcase bolts. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.71 © Copyright Polaris Sales Inc.
  • Page 129 Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.72 © Copyright Polaris Sales Inc.
  • Page 130 M8 bolts that retain the oil sump cover to the crankcase. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.73 © Copyright Polaris Sales Inc.

  • Page 131: Flywheel Installation

    50563) is installed, remove it before tightening the flywheel. TORQUE Flywheel Retaining Bolt: 133 ft-lbs (180 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.74 © Copyright Polaris Sales Inc.

  • Page 132: Stator Cover Installation

    TORQUE Stator Cover Screws: 9 ft-lb (12 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.75 © Copyright Polaris Sales Inc.

  • Page 133: Engine Assembly - Top End

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.76 © Copyright Polaris Sales Inc.

  • Page 134: Valve Sealing Test

    CYLINDER HEAD INSTALLATION 1. If necessary, rotate the engine so the cylinder is facing up. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.77 © Copyright Polaris Sales Inc.

  • Page 135: Camshaft Installation / Timing

    Exhaust Camshaft - PN 1204584 Cylinder Head Torque Procedure: Torque in sequence: 3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to Step 1: 9 ft-lbs (12 Nm) installation. Step 2: 26 ft-lb (35 Nm) Step 3: Additional 180°...
  • Page 136 Use new sprocket retaining bolts upon assembly. an open-end wrench to rotate camshafts slightly if needed. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.79 © Copyright Polaris Sales Inc.
  • Page 137 15. Remove the Cylinder Holding & Camshaft Timing Plate (PU-50563) from the end of the camshafts. 16. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.80...
  • Page 138 • Install the two mounting bolts. Torque fasteners to Camshaft Carrier Bolts: specification. 7 ft-lb (10 Nm) TORQUE 22. Apply Polaris PS-4 engine oil to the cam chain Tensioner Mounting Bolts: tensioner bore prior to assembly. Use a new 7 ft-lb (10 Nm) tensioner sealing washer.

  • Page 139: Camshaft Timing - Quick Reference

    CPS Mounting Hole Align Intake Marks With Surface Align Flywheel Mark in Mounting Hole 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.82 © Copyright Polaris Sales Inc.

  • Page 140: Valve Clearance Adjustment

    - PN 1204583 Exhaust Camshaft - PN 1204584 2. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. TORQUE Camshaft Carrier Bolts: 89 in-lbs (10 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.83...
  • Page 141 13. Refer to the appropriate tappet selection matrix (Intake or Exhaust) on the following pages and select the proper tappet. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.84 © Copyright Polaris Sales Inc.
  • Page 142 Camshaft Installation / Timing, page 3.78. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.85 © Copyright Polaris Sales Inc.

  • Page 143: Intake Valve Lash - Tappet Selection Matrix

    0.951-0.975 522 525 528 530 532 535 538 540 542 545 0.976-1.000 525 528 530 532 535 538 540 542 545 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.86 © Copyright Polaris Sales Inc.

  • Page 144: Exhaust Valve Lash - Tappet Selection Matrix

    0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.87 © Copyright Polaris Sales Inc.

  • Page 145: Valve Cover Installation

    7. Torque valve cover bolts to specification. TORQUE Valve Cover Bolts: 7 ft-lbs (10 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.88 © Copyright Polaris Sales Inc.

  • Page 146: Troubleshooting

    • Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup • Excessive piston-to-cylinder clearance 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.89 © Copyright Polaris Sales Inc.
  • Page 147 • Faulty hot light circuit • Thermostat stuck closed or not opening completely 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.90 © Copyright Polaris Sales Inc.
  • Page 148 • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.91 © Copyright Polaris Sales Inc.
  • Page 149 ENGINE NOTES 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 3.92 © Copyright Polaris Sales Inc.
  • Page 150 ................4.29 OPERATION OVERVIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 151 ..........4.46 ENGINE CONTROLLER REPROGRAMMING (REFLASH) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 152: General Information

    Bosch Automotive Service Solutions (PU-50621) or DSA at: www.diagsys.com Digital Wrench® SmartLink Module Kit - PU-47471 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 153 SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This module kit is used on all 8 pin connector-based Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.

  • Page 154: Efi Service Notes

    • Clean any connector before opening to prevent dirt from entering the system. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 155: Efi System Exploded View

    FUEL SYSTEM - GENERAL EFI SYSTEM EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 156: Efi System Component Locations

    5. Engine Coolant Temperature Sensor (ECT) - Located on the cylinder head below the intake manifold. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 157 - Connected to the left end of the fuel rail and top of intake track, retained on top by the fuel rail. the fuel pump. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 158 - Located next to the airbox behind the driver’s seat. - Located under the driver’s seat. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 159: Electronic Fuel Injection

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.10 © Copyright Polaris Sales Inc.

  • Page 160: Fuel Tank

    FUEL SYSTEM - GENERAL FUEL TANK FUEL TANK EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.11 © Copyright Polaris Sales Inc.

  • Page 161: Fuel Line Removal / Installation

    6. Be sure fuel line is routed and retained properly. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.12 © Copyright Polaris Sales Inc.

  • Page 162: Fuel Tank Removal

    5. Remove the fuel tank vent line (B) from the tank fitting. 6. Disconnect the fuel pump electrical harness (C). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.13 © Copyright Polaris Sales Inc.

  • Page 163: Fuel Tank Installation

    8. Install storage bins and driver and passenger seat bases. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.14 © Copyright Polaris Sales Inc.

  • Page 164: Fuel Pump

    • If the engine is stopped with the key switch "on" (as in the case of an accident). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.15 © Copyright Polaris Sales Inc.

  • Page 165: Fuel Pump Test

    2. Lift the rear cargo box to the raised position. 3. Locate the fuel pressure valve on top of the fuel rail. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.16 © Copyright Polaris Sales Inc.

  • Page 166: Fuel Pump Replacement

    NOTE If the pump still does not operate, replace the fuel pump assembly. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.17 © Copyright Polaris Sales Inc.
  • Page 167 Properly drain fuel into a suitable container. 6. Disconnect the fuel pump electrical harness (B). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.18 © Copyright Polaris Sales Inc.
  • Page 168 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.19 © Copyright Polaris Sales Inc.
  • Page 169 24. Install storage bin and driver’s seat base. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.20 © Copyright Polaris Sales Inc.

  • Page 170: Electronic Control Unit (Ecu)

    If a problem is encountered, and you circuits within the ECU. Signals to the ECU include: determine the ECU to be faulty, contact the Polaris ignition power (on/off), intake air temperature, manifold Service Department for specific handling instructions. Do absolute pressure (load), engine coolant temperature, not replace the ECU without factory authorization.
  • Page 171 “click” when the connector is fully closed. TORQUE ECU Retaining Screws:24 in-lbs (2.7 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.22 © Copyright Polaris Sales Inc.

  • Page 172: 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 173: Crankshaft Position Sensor (Cps)

    CPS and flywheel encoder ring for damage (see “CPS Replacement”). 4. If the resistance is incorrect, follow the “CPS Replacement” procedure. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.24 © Copyright Polaris Sales Inc.

  • Page 174: Cps Replacement

    7. Route CPS wire lead through wire clip and reconnect CPS harness connector. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.25 © Copyright Polaris Sales Inc.

  • Page 175: Temp / Manifold Absolute Pressure Sensor (T-Map)

    This sensor should only be tested using the Digital Wrench® Diagnostic Software (dealer only). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.26 © Copyright Polaris Sales Inc.

  • Page 176: Engine Coolant Temperature Sensor (Ect)

    Refer to Chapter 10 for additional ECT sensor 7. Torque the new ECT sensor to specification and information. Polaris dealers can test the sensor by using connect the vehicle harness to the sensor. Digital Wrench® Diagnostic Software (dealer only).
  • Page 177 FUEL SYSTEM - GENERAL 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.28 © Copyright Polaris Sales Inc.

  • Page 178: Pedal Position Sensor (Pps)

    If the PPS is faulty, the throttle pedal assembly must be replaced (see "PPS Replacement"). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.29 © Copyright Polaris Sales Inc.
  • Page 179 Throttle Pedal Asm Nuts: 18 ft-lbs (24 Nm)Pedal Bracket Nuts: 18 ft-lbs (24 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.30 © Copyright Polaris Sales Inc.

  • Page 180: Fuel Injectors

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.31 © Copyright Polaris Sales Inc.

  • Page 181: Fuel Injector Test

    4. Remove the passenger seat and storage bin and disconnect the negative battery cable. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.32 © Copyright Polaris Sales Inc.
  • Page 182 20. Start the engine briefly and inspect the fuel rail and injectors for fuel leaks. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.33 © Copyright Polaris Sales Inc.

  • Page 183: Ignition Coil

    4. Install the new ignition coil and/or high tension lead (s). TORQUE Ignition Coil Retaining Bolt: 8 ft-lbs (10.8 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.34 © Copyright Polaris Sales Inc.
  • Page 184 FUEL SYSTEM - GENERAL Secondary Test 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.35 © Copyright Polaris Sales Inc.

  • Page 185: Efi Diagnostics

    4. If more than one code exists, press the MODE button to advance to the next trouble code. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.36 © Copyright Polaris Sales Inc.
  • Page 186 Driver Circuit Open / Grounded P0264 Injector 2 (PTO) Driver Circuit Short to B+ P0265 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.37 © Copyright Polaris Sales Inc.
  • Page 187 IC CAN Communication with EPS Off Line (EPS DM1 not seen) 520230 U0131 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.38 © Copyright Polaris Sales Inc.
  • Page 188 Converter Fault - No Load ECU Analog to Digital Condition Exists 520307 P1532 Converter Fault - Voltage 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.39 © Copyright Polaris Sales Inc.
  • Page 189 Condition Exists 520309 P1534 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.40 © Copyright Polaris Sales Inc.

  • Page 190: Efi Troubleshooting

    • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.41 © Copyright Polaris Sales Inc.

  • Page 191: Digital Wrench® Operation

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

  • Page 192: Digital Wrench® Communication Errors

    The serial number is located on the right side of the screen. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.43 © Copyright Polaris Sales Inc.

  • Page 193: Digital Wrench® Version And Update

    2. Locate the “Service and Warranty” drop-down menu. 3. Click on “Digital Wrench Updates”. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. 4. The Digital Wrench® portal website should appear in a new web browser.
  • Page 194 Select "save" and download them to your PC before running the install. NOTE Versions and updates are subject to change. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.45 © Copyright Polaris Sales Inc.

  • Page 195: Digital Wrench® Feature Map

    FUEL SYSTEM - GENERAL DIGITAL WRENCH® FEATURE MAP ENGINE CONTROLLER REPROGRAMMING (REFLASH) Process Overview 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.46 © Copyright Polaris Sales Inc.
  • Page 196 ECU. voltage is as specified. The Digital Wrench® Engine Controller Reprogramming • Proceed to http://polaris.diagsys.com for specific (or “Reflash”) feature allows reprogramming of the ECU information and FAQs on how to troubleshoot fuel and ignition map. To successfully reprogram the communication problems.
  • Page 197 “Continue” icon to proceed to the Integrity Check and obtain a Request Code. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.48 © Copyright Polaris Sales Inc.
  • Page 198 10. Enter or paste (CTRL+V) the Request Code into the box. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.49 © Copyright Polaris Sales Inc.
  • Page 199 ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 4.50 © Copyright Polaris Sales Inc.
  • Page 200 ..................5.36 EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 201 ................. .5.49 SHOCK REPLACEMENT 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 202: Torque Specifications

    Steering Gearbox Bolts 16 ft-lbs (22 Nm) Steering Shaft Pinch Bolt 40 ft-lbs (54 Nm) (Non-EPS) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 203: Special Tools

    Shock Spring Compressor Tool 2870623 Multi-Function Pliers 2876389 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 204: Multi-Function Pliers

    Included in the tool kit, this multi-function pliers is designed to remove plastic push rivets and install body components. Detail View 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 205: Cab Frame Assembly

    *Vehicles with bucket seats and doors do not include Side Nets, Hip Bolster, or Head Rests. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 206 *Vehicles with bucket seats and doors do not include Side Nets, Hip Bolster, or Head Rests. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 207: Doors (Le Only)

    BODY / STEERING / SUSPENSION DOORS (LE ONLY) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 208 (Torque when Fastening Ref. 16 to the vehicle) SCREW Torque: 8 ft-lbs. (10 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 209: Chassis

    BODY / STEERING / SUSPENSION CHASSIS MAIN FRAME / FRAME SUPPORTS / FRONT BUMPER 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.10 © Copyright Polaris Sales Inc.
  • Page 210 BODY / STEERING / SUSPENSION RANGER CREW 900 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.11 © Copyright Polaris Sales Inc.

  • Page 211: Body Components

    BODY / STEERING / SUSPENSION BODY COMPONENTS DASH PANELS / GLOVE BOX 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.12 © Copyright Polaris Sales Inc.

  • Page 212: Hood / Front Fenders / Front Fascia

    BODY / STEERING / SUSPENSION HOOD / FRONT FENDERS / FRONT FASCIA 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.13 © Copyright Polaris Sales Inc.

  • Page 213: Floor / Rear Fenders / Skid Plate / Storage

    BODY / STEERING / SUSPENSION FLOOR / REAR FENDERS / SKID PLATE / STORAGE 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.14 © Copyright Polaris Sales Inc.
  • Page 214 BODY / STEERING / SUSPENSION RANGER CREW 900 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.15 © Copyright Polaris Sales Inc.

  • Page 215: Seat Mounting / Seat Belts

    BODY / STEERING / SUSPENSION SEAT MOUNTING / SEAT BELTS 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.16 © Copyright Polaris Sales Inc.
  • Page 216 BODY / STEERING / SUSPENSION RANGER CREW 900 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.17 © Copyright Polaris Sales Inc.

  • Page 217: Bucket Seats

    BODY / STEERING / SUSPENSION BUCKET SEATS 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.18 © Copyright Polaris Sales Inc.
  • Page 218 TORQUE: 24 in-lbs. (2.7 Nm) *Crew and Bucket seat models use the same center console. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.19 © Copyright Polaris Sales Inc.

  • Page 219: Rear Cargo Box

    BODY / STEERING / SUSPENSION REAR CARGO BOX TAILGATE / CARGO BOX PANELS 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.20 © Copyright Polaris Sales Inc.

  • Page 220: Cargo Box Support

    BODY / STEERING / SUSPENSION CARGO BOX SUPPORT 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.21 © Copyright Polaris Sales Inc.

  • Page 221: Box Removal

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.22 © Copyright Polaris Sales Inc.

  • Page 222: Body Component Removal

    3. Remove the (2) T-40 Torx-head screws (C) retaining the front fascia to the upper radiator brackets. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.23 © Copyright Polaris Sales Inc.

  • Page 223: Front Fenders

    6. Carefully pull the front fascia straight out to remove it from the vehicle. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.24 © Copyright Polaris Sales Inc.

  • Page 224: Dash Panels / Glove Box Removal

    11. Carefully remove the dash storage panel. ROCKER PANELS 1. Remove the seat bottom and under seat storage box. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.25 © Copyright Polaris Sales Inc.
  • Page 225 If removing the LH panel, loosen the hose clamp (R) retaining the fuel fill hose to the LH panel. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.26 © Copyright Polaris Sales Inc.

  • Page 226: Rocker Panels - Crew

    WARNING: Gasoline is extremely flammable and explosive under certain conditions. 8. Installation is reverse of removal. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.27 © Copyright Polaris Sales Inc.

  • Page 227: Main Floor

    4. Lift and remove the main floor from the vehicle. 8. Remove the lower steering shaft (see “Lower Steering Shaft Removal”). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.28 © Copyright Polaris Sales Inc.

  • Page 228: Rear Floor - Crew

    4. Remove (4) T-25 Torx fasteners (A) Fig. 1 securing the fuse box to the center under seat storage box. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.29 © Copyright Polaris Sales Inc.
  • Page 229 11. Lift the floor panel out of the vehicle. 12. Installation is the reverse order of removal. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.30 © Copyright Polaris Sales Inc.

  • Page 230: Steering Assembly

    BODY / STEERING / SUSPENSION STEERING ASSEMBLY EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.31 © Copyright Polaris Sales Inc.

  • Page 231: Steering Wheel Removal (Non-Eps Models)

    10. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.32 © Copyright Polaris Sales Inc.

  • Page 232: Steering Shaft Removal (Non-Eps Models)

    Replacement” procedure for installation. Be sure the lower spacers are still on the steering shaft. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.33 © Copyright Polaris Sales Inc.

  • Page 233: Power Steering Unit Removal

    3. Secure the power steering unit and remove the (4) location. fasteners (A) retaining the power steering mount to the frame. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.34 © Copyright Polaris Sales Inc.
  • Page 234 9. Install the upper steering shaft pinch bolt and torque to specification. TORQUE Upper Power Steering Shaft Pinch Bolt:15 ft-lbs (20 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.35 © Copyright Polaris Sales Inc.

  • Page 235: Front A-Arms

    BODY / STEERING / SUSPENSION FRONT A-ARMS EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.36 © Copyright Polaris Sales Inc.

  • Page 236: Front Lower A-Arm Removal

    Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.37 © Copyright Polaris Sales Inc.

  • Page 237: Front Upper A-Arm Removal

    A-arm fastener to specification. TORQUE Upper A-Arm to Frame:40 ft-lbs (54 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.38 © Copyright Polaris Sales Inc.

  • Page 238: Ball Joint Service

    A-arm to gain enough clearance to install ball joint tool (PU-50506) on the lower ball joint. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.39 © Copyright Polaris Sales Inc.

  • Page 239: Ball Joint Installation

    New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.40 © Copyright Polaris Sales Inc.
  • Page 240 Mounting Bolts: 30 ft-lbs (41 Nm)Wheel Nuts (Aluminum): 120 ft-lbs (163 Nm)Wheel Nuts (Steel): 60 ft-lbs (81 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.41 © Copyright Polaris Sales Inc.

  • Page 241: Rear A-Arms

    BODY / STEERING / SUSPENSION REAR A-ARMS EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.42 © Copyright Polaris Sales Inc.

  • Page 242: Rear Upper A-Arm Removal

    A-arm. Torque new fastener to specification. TORQUE Shock Mounting Bolts:40 ft-lbs (54 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.43 © Copyright Polaris Sales Inc.

  • Page 243: Rear Lower A-Arm Removal

    7. Remove the fastener retaining the lower A-arm to the bearing carrier. 8. Remove the lower A-arm from the vehicle. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.44 © Copyright Polaris Sales Inc.

  • Page 244: Rear Lower A-Arm Installation

    Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.45 © Copyright Polaris Sales Inc.

  • Page 245: Rear Stabilizer Bar / Linkage

    BODY / STEERING / SUSPENSION REAR STABILIZER BAR / LINKAGE EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.46 © Copyright Polaris Sales Inc.

  • Page 246: Removal / Installation

    17 ft-lbs (23 Nm) TORQUE Stabilizer Bar Linkage Bushing: 17 ft-lbs (23 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.47 © Copyright Polaris Sales Inc.

  • Page 247: Decal Replacement

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.48 © Copyright Polaris Sales Inc.

  • Page 248: Shocks / Springs

    SHOCK REPLACEMENT 1. Remove the shock and note the spring preload cam setting. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.49 © Copyright Polaris Sales Inc.
  • Page 249 BODY / STEERING / SUSPENSION NOTES 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 5.50 © Copyright Polaris Sales Inc.
  • Page 250 ..............6.29 EXPLODED VIEW 2014 (NON-EBS) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 251 TROUBLESHOOTING ..................6.37 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 252: Special Tools And Supplies

    1-800-345-2233 or http://polaris.service-solutions.com SPECIAL SUPPLIES PART NUMBER Loctite® 648 and 263 RTV Silicone Sealer 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 253: High Altitude Clutch Charts

    Models 1500-3700 Meters 27-83 Wht / Blu 7044015 (5000 - 12000 Feet) (5632754) (7044111) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 254: Pvt System Overview

    During the development of driven clutches are continually shifting to maintain the Polaris vehicle, the PVT system is matched first to the optimum engine RPM. At full throttle a perfectly matched engine power curve; then to average riding conditions PVT system should hold engine RPM at the peak of the vehicle’s...

  • Page 255: Pvt Break-In (Drive Belt / Clutches)

    PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water forging. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 256: Overheating / Diagnosis

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

  • Page 257: Pvt System Service

    CLUTCHING PVT SYSTEM SERVICE PVT COVERS AND DUCTING COMPONENTS 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 258: Pvt Disassembly

    (A). Loosen the PVT inlet and outlet hose clamps (B) and remove the ducting hoses from the vehicle. Drive Clutch Holding Tool 9314177-A 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 259 6. Remove the fuel line (D) and wiring harness (E) from the inner clutch cover restraints. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.10 © Copyright Polaris Sales Inc.

  • Page 260: Pvt Assembly

    Apply a light film of grease to the splines on the shaft. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.11 © Copyright Polaris Sales Inc.
  • Page 261 (G) located on the PVT outlet duct hose. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.12 © Copyright Polaris Sales Inc.

  • Page 262: Drive Belt

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.13 © Copyright Polaris Sales Inc.

  • Page 263: Belt Inspection

    2. Install the outer clutch cover and (8) screws. Torque screws to specification. TORQUE Outer Clutch Cover Retaining Screws:54 in-lbs (6.1 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.14 © Copyright Polaris Sales Inc.

  • Page 264: Drive Clutch Service

    CLUTCHING DRIVE CLUTCH SERVICE DRIVE CLUTCH EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.15 © Copyright Polaris Sales Inc.

  • Page 265: Clutch Disassembly

    Replace the cover bushing if more brass than Teflon® is visible on the bushing. Refer to bushing replacement in this chapter. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.16 © Copyright Polaris Sales Inc.

  • Page 266: Drive Clutch Spring Inspection

    “Roller, Pin and Thrust Washer Inspection”. TORQUE Shift Weight Fasteners (Nuts):20 in-lbs (2.3 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.17 © Copyright Polaris Sales Inc.

  • Page 267: Button To Tower Clearance Inspection

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.18 © Copyright Polaris Sales Inc.

  • Page 268: Roller, Pin, And Thrust Washer Inspection

    Take care not to damage roller bushing or bearing surface of the new pin during installation. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.19 © Copyright Polaris Sales Inc.

  • Page 269: Moveable Sheave Bushing Inspection

    Replace the cover bushing if more brass than Teflon® is visible on the bushing. Refer to “Bushing Service” in this chapter. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.20 © Copyright Polaris Sales Inc.

  • Page 270: Bushing Service

    5020629 /Installation Tool (all clutches) P-90 Driven Clutch Cover Bushing 5020631 Removal Tool 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.21 © Copyright Polaris Sales Inc.
  • Page 271 11. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. Drive Clutch Bushing Installation 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.22 © Copyright Polaris Sales Inc.

  • Page 272: Clutch Assembly

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.23 © Copyright Polaris Sales Inc.
  • Page 273 9. Torque cover bolts evenly to specification. TORQUE Drive Clutch Cover Bolts: 100 in-lbs (12 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.24 © Copyright Polaris Sales Inc.

  • Page 274: Driven Clutch Service

    NOTE Spring is compression only and has no torsional wind. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.25 © Copyright Polaris Sales Inc.
  • Page 275 8. Check the rollers in the stationary sheave for wear. If rollers are worn, a new driven clutch assembly may be needed. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.26 © Copyright Polaris Sales Inc.

  • Page 276: Clutch Assembly

    3. Install the spring into the inner retainer. 4. Install the spacer over the shaft. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.27 © Copyright Polaris Sales Inc.
  • Page 277 7. Apply and hold downward pressure on the outer spring retainer. Carefully install the snap ring. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.28 © Copyright Polaris Sales Inc.

  • Page 278: 2014 Driven Clutch Service (Non-Ebs)

    Compressor PU-50518. Spin the compressor tool handle down to apply downward pressure on the spring cup (C). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.29 © Copyright Polaris Sales Inc.

  • Page 279: Clutch Assembly 2014 (Non-Ebs)

    5. Install driven clutch assembly and drive belt. NOTE: Spring is compression only and has no torsional wind. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.30 © Copyright Polaris Sales Inc.

  • Page 280: 2014 Driven Clutch Service (Ebs)

    CLUTCHING 2014 DRIVEN CLUTCH SERVICE (EBS) EXPLODED VIEW 2014 (EBS) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.31 © Copyright Polaris Sales Inc.

  • Page 281: Clutch Disassembly (Ebs)

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.32 © Copyright Polaris Sales Inc.

  • Page 282: Clutch Inspection

    3. If removed, inspect the outer clutch rollers and roller pins for excessive wear or damage. Replace as needed. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.33 © Copyright Polaris Sales Inc.

  • Page 283: Clutch Assembly 2014 (Ebs)

    Refer to the Polaris Electronic Parts catalog for specific parts availability. CLUTCH ASSEMBLY 2014 (EBS) 1. Line up the “X” on the moveable sheave with the “X”...
  • Page 284 5. Install the inner clutch rollers, thrust washers and E- rings onto the spider if previously disassembled. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.35 © Copyright Polaris Sales Inc.
  • Page 285 10. Use a T25 Torx driver to install the four screws and torque them to specification. NOTE Torque T25 Torx Screws:47 in-lbs (5.3 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.36 © Copyright Polaris Sales Inc.

  • Page 286: Troubleshooting

    -Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.37 © Copyright Polaris Sales Inc.
  • Page 287 -Drive clutch bushings stick -Inspect and repair clutches. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 6.38 © Copyright Polaris Sales Inc.
  • Page 288 ..............7.32 DRIVE SHAFT CUTAWAY VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 289: Special Tools

    30 ft-lbs (41 Nm) Front Prop Shaft Flex Bearing 40 ft-lbs (54Nm) Mounting Bolts 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 290: Front Bearing Carrier

    Visually inspect for moisture, dirt or corrosion. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 291: Bearing Replacement

    Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 292: Bearing Carrier Installation

    Install washers with domed side out. TORQUE Front Hub Castle Nut:75 ft-lbs (102 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 293 Install the center cap and/or rubber dust cap. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 294: Front Drive Shaft

    4. Perform the “Bearing Carrier Installation” procedure listed under the “FRONT BEARING CARRIER” section within this chapter. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 295: Front Propshaft

    10. Remove the propshaft assembly through the rear floor opening. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 296 6. Install front section of the propshaft. 7. Install the front gearcase (see “Front Gearcase Removal”). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 297: Propshaft U-Joint Service

    2. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.10 © Copyright Polaris Sales Inc.

  • Page 298: Assembly

    4. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.11 © Copyright Polaris Sales Inc.

  • Page 299: Front Gearcase - Centralized Hilliard

    Gearcase Housing Drain Plug, Magnetic Clutch Housing (Ring Gear) Retaining Ring, External Roll Cage 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.12 © Copyright Polaris Sales Inc.

  • Page 300: All Wheel Drive Operation

    The front drive will remain engaged until the torque requirement goes away (i. e. rear wheels regain traction). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.13 © Copyright Polaris Sales Inc.

  • Page 301: Awd Diagnosis

    Serious injury may result if machine tips or falls.Be sure machine is secure before beginningthis service procedure. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.14 © Copyright Polaris Sales Inc.

  • Page 302: Front Gearcase Disassembly / Inspection

    9. Remove the front gearcase from the left-hand side between the upper and lower control arms. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.15 © Copyright Polaris Sales Inc.
  • Page 303 NOTE Nylon spacer is non-serviceable and should not be removed. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.16 © Copyright Polaris Sales Inc.
  • Page 304 Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.17 © Copyright Polaris Sales Inc.
  • Page 305 Most parts are to be replaced as an assembly or as a complete kit. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.18 © Copyright Polaris Sales Inc.

  • Page 306: Front Gearcase Assembly

    4. Install the RH output hub into the gearcase housing. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.19 © Copyright Polaris Sales Inc.
  • Page 307 Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.20 © Copyright Polaris Sales Inc.

  • Page 308: Front Gearcase Installation

    7. Install the drive shafts into the front gearcase (see “FRONT DRIVE SHAFT - Installation”). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.21 © Copyright Polaris Sales Inc.
  • Page 309 Refer to Chapter 2 for fluid fill and change information. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.22 © Copyright Polaris Sales Inc.

  • Page 310: Rear Bearing Carrier

    8. Remove the bearing carrier. Inspect the bearing again for smoothness and side to side movement, replace as needed. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.23 © Copyright Polaris Sales Inc.

  • Page 311: Bearing Replacement

    8. Wipe the housing clean of any excess compound and install the snap ring (L). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.24 © Copyright Polaris Sales Inc.
  • Page 312 Wheel Nuts:Steel Wheels: 60 ft-lbs (81 Nm) Aluminum Wheels: 120 ft-lbs (163 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.25 © Copyright Polaris Sales Inc.

  • Page 313: Installation

    4. Refer to the “DRIVE SHAFT SERVICE” section if repairing the drive shaft. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.26 © Copyright Polaris Sales Inc.

  • Page 314: Drive Shaft Service

    1. Use a side cutters to cut and discard the boot clamps. NOTE Tap on inner race only! 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.27 © Copyright Polaris Sales Inc.
  • Page 315 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.28 © Copyright Polaris Sales Inc.

  • Page 316: Inner Plunging Joint / Boot Replacement

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.29 © Copyright Polaris Sales Inc.
  • Page 317 10. Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.30 © Copyright Polaris Sales Inc.
  • Page 318 Make sure the boot is not dimpled or collapsed. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.31 © Copyright Polaris Sales Inc.

  • Page 319: Drive Shaft Cutaway View

    FINAL DRIVE DRIVE SHAFT CUTAWAY VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 7.32 © Copyright Polaris Sales Inc.
  • Page 320 ..................8.32 EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 321: Specifications

    Transmission Case 15-20 ft-lbs (20-27 Nm) Screws Speed Sensor Screw 9-12 ft-lbs (12-16 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 322: Transmission Mounting And Torque Values

    TRANSMISSION TRANSMISSION MOUNTING AND TORQUE VALUES 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 323: Shift Lever

    5. Remove the retaining ring (J) and slide the shift lever (D) off the mounting bracket and out from the frame. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 324: Shift Cable

    If transmission still ratchets after cable adjustment, the transmission will require service. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 325: Transmission Removal

    Correct Drive Clutch Puller P/N 2872085 9. Remove the vent line (K) from the transmission fitting. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 326 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 327 17. Remove the rear transmission mount bolt (W). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 328 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 329: Transmission Installation

    4. Align the front transmission mounting holes with the transmission joint bracket mounting holes. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.10 © Copyright Polaris Sales Inc.
  • Page 330 Rear Transmission Mount Bolt:40 ft-lbs (54 Nm) 13. Remove the lifting straps and overhead or portable hoist. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.11 © Copyright Polaris Sales Inc.
  • Page 331 Be sure to tug on the fuel line after installing it to make sure it is secured. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.12 © Copyright Polaris Sales Inc.
  • Page 332 “Transmission Lubrication”). FLUID CAPACITY Recommended Transmission Lubricant:AGL(PN 2878068) (Quart)Capacity: 41 oz. (1200 ml) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.13 © Copyright Polaris Sales Inc.

  • Page 333: Transmission Service

    The rear drive shafts are now dependent on the differential allowing for tighter turns. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.14 © Copyright Polaris Sales Inc.

  • Page 334: Transmission Disassembly

    4. Remove E-clip (C) that retains spring washer (D), flat washer (D) and gear switch (E). Remove the switch. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.15 © Copyright Polaris Sales Inc.
  • Page 335 Do not pry on case sealing surfaces.Use only the designated pry pointson the transmission. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.16 © Copyright Polaris Sales Inc.
  • Page 336 Gear Cluster Disassembly 17. Slide engagement dog (X) off of shift fork guides. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.17 © Copyright Polaris Sales Inc.
  • Page 337 Failure to remove pinion shaft, will result in damage to the snorkel shaft. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.18 © Copyright Polaris Sales Inc.
  • Page 338 33. Lightly tap on the bearing from the opposite side to remove it from the snorkel tube. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.19 © Copyright Polaris Sales Inc.

  • Page 339: Planetary Differential Disassembly

    1. Use a scribe to mark the differential cover and ring gear prior to disassembly. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.20 © Copyright Polaris Sales Inc.

  • Page 340: Planetary Differential Bushing Replacement

    2. Thoroughly clean the bore of the ring gear and check for any unwanted burs. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.21 © Copyright Polaris Sales Inc.
  • Page 341 6. Thoroughly clean the bore of the planet gear and check for any unwanted burs. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.22 © Copyright Polaris Sales Inc.

  • Page 342: Planetary Differential Assembly

    13. Thoroughly clean the bore of the side gear and check for any unwanted burs. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.23 © Copyright Polaris Sales Inc.

  • Page 343: Gear / Shaft / Bearing Inspection

    Differential Cover Screws:18-22 ft-lbs (24-30 Nm) GEAR / SHAFT / BEARING INSPECTION 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.24 © Copyright Polaris Sales Inc.

  • Page 344: Snorkel Gear Backlash Procedure

    8. Apply Loctite® 242 to the threads of the bearing cover retaining screws. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.25 © Copyright Polaris Sales Inc.
  • Page 345 Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.26 © Copyright Polaris Sales Inc.
  • Page 346 Torque specification. TORQUE Shift Fork Screws:7-10 ft-lbs (10-14 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.27 © Copyright Polaris Sales Inc.
  • Page 347 Shift fork pins should be offset towards the input shaft as shown above. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.28 © Copyright Polaris Sales Inc.
  • Page 348 28. Apply a continuous bead of Crankcase 3 Bond Sealant (PN 2871557) to the left hand transmission mating surface. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.29 © Copyright Polaris Sales Inc.
  • Page 349 Sector Cover Bolts: 9-12 ft-lbs (12-16 Nm)Fill / Drain Plug: 10-14 ft-lbs (14-19 Nm)Bellcrank Nut: 12-18 ft- lbs (16-24 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.30 © Copyright Polaris Sales Inc.

  • Page 350: Troubleshooting

    If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.31 © Copyright Polaris Sales Inc.

  • Page 351: Transmission Exploded View

    TRANSMISSION TRANSMISSION EXPLODED VIEW EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.32 © Copyright Polaris Sales Inc.
  • Page 352 Shift Dog, Park 104. Screw, M8 x 1.25 x 25 Bearing, Ball Gear, 46T 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.33 © Copyright Polaris Sales Inc.
  • Page 353 TRANSMISSION NOTES 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 8.34 © Copyright Polaris Sales Inc.
  • Page 354 ................9.27 CALIPER DISASSEMBLY 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 355 ................... .9.32 BRAKES LOCK 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 356: General Specifications

    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) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.
  • Page 357 Caliper Mounting Bolts (Rear) Front Brake Scraper Screws Master Cylinder Mounting Bolts Pedal Mount Bracket Nuts 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 358: Brake System Service Notes

    • DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake cleaning products. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 359: Brake Noise Troubleshooting

    Noise is from other source (axle, hub, disc or wheel) other sources. Inspect and repair as necessary 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 360: Hydraulic Brake System Operation

    BRAKES HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake system.

  • Page 361: Brake System Assembly View

    BRAKES BRAKE SYSTEM ASSEMBLY VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 362: Master Cylinder

    4. Loosen the brake line banjo bolt (D) and brake switch (E) allowing the fluid to drain. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

  • Page 363: Foot Brake Pedal

    2. Reverse “Removal” steps 1-3 to complete foot brake installation. 3. Use new retaining clips upon installation. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.10 © Copyright Polaris Sales Inc.

  • Page 364: Brake Bleeding / Fluid Change

    Maintain at least 1/2"(1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder. Polaris DOT 4 Brake Fluid(P/N 2872189) 13. Tighten bleeder screw and remove bleeder hose. Torque bleed screw to specification. 5. Begin bleeding procedure with caliper furthest from master cylinder.
  • Page 365 1/2" (1.3 cm). 17. Check brake system for fluid leaks. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.12 © Copyright Polaris Sales Inc.

  • Page 366: Front Brake Pads

    Support caliper to avoid kinking or bending brake line. 6. Remove the inner pad from the bracket and caliper. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.13 © Copyright Polaris Sales Inc.

  • Page 367: Pad Inspection

    Maintain at least 1/2, (12.7 mm) of brake fluid in reservoir to prevent air from entering brake system. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.14 © Copyright Polaris Sales Inc.

  • Page 368: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.15 © Copyright Polaris Sales Inc.

  • Page 369: Front Caliper Service

    4. Place a container below the caliper to catch brake fluid when removing line. Remove brake line (A) from caliper. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.16 © Copyright Polaris Sales Inc.

  • Page 370: Caliper Disassembly

    The piston sealing surfaces will become damaged if a standard pliers is used. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.17 © Copyright Polaris Sales Inc.

  • Page 371: Caliper Inspection

    Limit: 1.368” (34.75 mm) 3. Inspect brake disc and pads as outlined in this chapter. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.18 © Copyright Polaris Sales Inc.

  • Page 372: Caliper Assembly

    If brake disc scraper (A) was removed, be sure to reinstall it upon caliper installation. 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
  • Page 373 If new brake pads are installed, brake burnishing is recommended (see “FRONT BRAKE PADS - Brake Burnishing Procedure”). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.20 © Copyright Polaris Sales Inc.

  • Page 374: Front Brake Disc

    Brake Disc Thickness VarianceService Limit: .002” Brake Disc Runout:Service Limit .010” (.254 mm) (.051 mm)difference between measurements 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.21 © Copyright Polaris Sales Inc.

  • Page 375: Disc Removal / Replacement

    TORQUE Front Brake Disc Mounting Bolts:18 ft-lbs (24 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.22 © Copyright Polaris Sales Inc.

  • Page 376: Rear Brake Pads

    Rear Brake Pad ThicknessNew .298 + .007” (7.56 + .178 mm)Service Limit .180” (4.6 mm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.23 © Copyright Polaris Sales Inc.

  • Page 377: Pad Installation

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.24 © Copyright Polaris Sales Inc.

  • Page 378: Rear Caliper Service

    BRAKES REAR CALIPER SERVICE CALIPER EXPLODED VIEW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.25 © Copyright Polaris Sales Inc.

  • Page 379: Caliper Exploded View Ranger Crew

    BRAKES CALIPER EXPLODED VIEW RANGER CREW 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.26 © Copyright Polaris Sales Inc.

  • Page 380: Caliper Removal

    6. Clean the brake disc, caliper body and caliper pistons with brake cleaner or alcohol. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.27 © Copyright Polaris Sales Inc.

  • Page 381: Caliper Inspection

    MEASUREMENT Rear Caliper Piston Bore I.D.:Standard: 1.505” (38.23 mm)Service Limit: 1.507” (38.28 mm) 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.

  • Page 382: Caliper Installation

    3. Install the pad adjustment screw (C) and turn until stationary pad contacts disc, then back off 1/2 turn. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.29 © Copyright Polaris Sales Inc.

  • Page 383: Rear Brake Disc

    Brake Disc Thickness Variance:Service Limit .002” (.051 mm)difference between measurements Brake Disc RunoutService Limit .010” (.254 mm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.30 © Copyright Polaris Sales Inc.

  • Page 384: Disc Removal / Replacement

    TORQUE Rear Brake Disc Mounting Bolts:28 ft-lbs (38 Nm) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.31 © Copyright Polaris Sales Inc.

  • Page 385: Troubleshooting

    • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 9.32 © Copyright Polaris Sales Inc.
  • Page 386 FUEL SENDER ..................10.22 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.1 © Copyright Polaris Sales Inc.
  • Page 387 ..........10.44 EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.2 © Copyright Polaris Sales Inc.

  • Page 388: General Information

    The following components can be accessed under the hood. • Voltage Regulator (in front of radiator) • Terminal Block 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.3 © Copyright Polaris Sales Inc.

  • Page 389: Switches / Controls

    Pins 7 and 8 provide power and ground to light the switch lamp. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.4 © Copyright Polaris Sales Inc.

  • Page 390: Ignition Key Switch

    Pins 7 and 8 provide power and ground to light the switch lamp. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.5 © Copyright Polaris Sales Inc.

  • Page 391: Transmission (Gear Position) Switch

    2. Test transmission switch for continuity in each gear position and compare to the specifications below. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.6 © Copyright Polaris Sales Inc.

  • Page 392: Vehicle Speed Sensor

    4. Be sure connections are good and 9V battery is in good condition. If the light flashes, the sensor is good. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.7 © Copyright Polaris Sales Inc.

  • Page 393: Rear Diff Solenoid

    Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.8 © Copyright Polaris Sales Inc.
  • Page 394 ELECTRICAL 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.9 © Copyright Polaris Sales Inc.

  • Page 395: Instrument Cluster

    Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.10 © Copyright Polaris Sales Inc.

  • Page 396: Rider Information Display

    12. Neutral Gear Indicator - LED icon illuminates when gear selector is in the neutral (N) position. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.11 © Copyright Polaris Sales Inc.

  • Page 397: Information Display Area

    Engine hours are logged anytime the engine is running. Total hours can not be reset. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.12 © Copyright Polaris Sales Inc.
  • Page 398 8. Press and hold the MODE button until the hour segment flashes. Release the button. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.13 © Copyright Polaris Sales Inc.

  • Page 399: Diagnostic Mode

    5. If more than one code exists, press the MODE button to advance to the next trouble code. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.14 © Copyright Polaris Sales Inc.

  • Page 400: Instrument Cluster Removal

    Ground High Beam Input Fuel Level Sensor 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.15 © Copyright Polaris Sales Inc.

  • Page 401: Instrument Cluster Installation

    4. Connect the wire harness to the instrument cluster. 5. Install the upper dash panel and push rivets. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.16 © Copyright Polaris Sales Inc.

  • Page 402: Audio System (Le Only)

    80% of all electrical issues are caused by bad/failed connections and grounds. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.17 © Copyright Polaris Sales Inc.

  • Page 403: Headlights

    4. Turn the bulb counterclockwise and remove it from the headlight housing. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.18 © Copyright Polaris Sales Inc.

  • Page 404: Headlight Housing Removal

    4. Install the Torx-head screw and push rivet retaining the upper right portion of the front fender. 5. Install the hood. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.19 © Copyright Polaris Sales Inc.
  • Page 405 ELECTRICAL 6. Adjust headlights using the “Headlight Adjustment” procedure. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.20 © Copyright Polaris Sales Inc.

  • Page 406: Tail Light / Brake Light

    5. Test the tail light / brake light after installation to verify proper function. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.21 © Copyright Polaris Sales Inc.

  • Page 407: Efi Diagnostics

    6. If none of the conditions exist, the fuel sender assembly is faulty. Replace the fuel pump assembly (see Chapter 4). 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.22 © Copyright Polaris Sales Inc.

  • Page 408: Cooling System

    ELECTRICAL COOLING SYSTEM COOLING SYSTEM BREAK-OUT DIAGRAM 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.23 © Copyright Polaris Sales Inc.

  • Page 409: Fan Control Circuit Operation / Testing

    If the coolant temperature sensor or circuit malfunctions the radiator fan will default to 'ON' while the engine is running. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.24 © Copyright Polaris Sales Inc.

  • Page 410: Fuse Box: Fuses / Relays / Circuit Breaker

    30-amp fuse and relay. Refer to “EPS System Breakout” for EPS electrical component details. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.25 © Copyright Polaris Sales Inc.

  • Page 411: Fuse Box Detail

    ELECTRICAL FUSE BOX DETAIL 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.26 © Copyright Polaris Sales Inc.

  • Page 412: Relay Operation

    FAN RELAY provides power to the following system: • Rear Differential Solenoid • Fan Motor 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.27 © Copyright Polaris Sales Inc.
  • Page 413 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.28 © Copyright Polaris Sales Inc.

  • Page 414: Charging System

    NOTE 2. With engine off, and the key switch and lights in the Charging system damage will occur if incompatible components are installed. Always reference Polaris ON position, the ammeter should read negative Electric Parts Catalog for proper part numbers.

  • Page 415: Stator (Alternator) Replacement

    Voltage readings according to RPM. Test each leg at the specified RPM in the table. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.30 © Copyright Polaris Sales Inc.

  • Page 416: Regulator / Rectifier

    (C). Remove the regulator (A) and heat sink plate (D) from the vehicle. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.31 © Copyright Polaris Sales Inc.

  • Page 417: Charging System Testing Flow Chart

    Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched: 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.32 © Copyright Polaris Sales Inc.

  • Page 418: Battery Service

    2. If the voltage is below 12.6 V, the battery will need to be recharged (see “Charging Procedure”). To service a Maintenance Free battery: 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.33 © Copyright Polaris Sales Inc.

  • Page 419: Battery Removal / Installation

    NOTE To perform this test, use a load testing device that has an Battery charge can be maintained by using a Polaris adjustable load. Apply a load of three times the ampere- battery tender charger or by charging once a month to hour rating.

  • Page 420: Battery Charging Procedure

    9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.35 © Copyright Polaris Sales Inc.

  • Page 421: Starter System

    The negative (-) battery cable is mounted to the engine using the upper starter mounting bolt / stud. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.36 © Copyright Polaris Sales Inc.

  • Page 422: Starter Motor Installation

    Green / White wire. (bendix) with the flywheel. This helps prevent binding and starter damage. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.37 © Copyright Polaris Sales Inc.
  • Page 423 • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.38 © Copyright Polaris Sales Inc.

  • Page 424: Starting System Testing Flow Chart

    ELECTRICAL STARTING SYSTEM TESTING FLOW CHART 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.39 © Copyright Polaris Sales Inc.

  • Page 425: Electronic Power Steering (Eps)

    WIRE COLOR FUNCTION the system will illuminate a fault indicator and transition to a normal mechanically coupled steering system. The ORANGE (2-Pin) Main Power (30A Protected) system is Polaris Digital Wrench® compatible for simplified diagnostics system troubleshooting BROWN (2-Pin) Ground through the vehicle’s diagnostic port.

  • Page 426: Eps System Breakout

    ELECTRICAL EPS SYSTEM BREAKOUT 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.41 © Copyright Polaris Sales Inc.

  • Page 427: Eps Troubleshooting (Power Steering Non-Functional With Mil On)

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.42 © Copyright Polaris Sales Inc.

  • Page 428: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.43 © Copyright Polaris Sales Inc.

  • Page 429: Eps Troubleshooting (Using Digital Wrench®)

    ELECTRICAL EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual 10.44 © Copyright Polaris Sales Inc.
  • Page 430 2013 RANGER XP 900 (NON-EPS)
  • Page 431 2013 RANGER XP 900 (NON-EPS)
  • Page 432 2013 RANGER XP 900 (EPS)
  • Page 433 2013 RANGER XP 900 (EPS)
  • Page 434 2013 RANGER XP 900 (CARGO BOX)
  • Page 443 Digital Wrench Communication Errors......4.43 Camshaft Timing Digital Wrench Diagnostic Software.......4.42 Quick Reference ............3.82 Digital Wrench Versions..........4.42 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual IX.1 © Copyright Polaris Sales Inc.
  • Page 444 Exhaust Valve Lash - Tappet Selection Matrix....3.87 Front Drive Shaft, Removal/Installation ......7.7 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual IX.2 © Copyright Polaris Sales Inc.
  • Page 445 Maintenance, Brake System ........2.40 Regulator .............. 10.31 Maintenance, Cooling System........2.27 Relays ..............10.27 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual IX.3 © Copyright Polaris Sales Inc.
  • Page 446 Suspension Spring Adjustment........2.39 VIN Number .............. 1.2 Switch, AWD/2WD/TURF..........10.5 Voltage Drop Test ............ 10.36 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual IX.4 © Copyright Polaris Sales Inc.
  • Page 447 Water Pump Service .......... 3.21, 3.23 Wheel Alignment ............2.37 Wheel, Installation .............2.31 Wheel, Removal............2.31 9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual IX.5 © Copyright Polaris Sales Inc.

This manual is also suitable for:

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