Polaris RANGER XP 1000 2020 Owner's Manual
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Polaris RANGER XP 1000 2020 Owner's Manual

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2020
RANGER XP 1000
EU / Zugmaschine
Owner's Manual
for Maintenance and Safety

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  • Page 1 2020 RANGER XP 1000 EU / Zugmaschine Owner's Manual for Maintenance and Safety...
  • Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone. Downloaded from ManualsNet.com search engine...
  • Page 3 2020 Owner’s Manual RANGER® XP 1000 EU / Zugmaschine Downloaded from ManualsNet.com search engine...
  • Page 4 POLARIS®, RANGER®, and POLARIS GENERAL™ are trademarks of POLARIS Industries Inc. Copyright 2019 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 6 WELCOME Downloaded from ManualsNet.com search engine...

  • Page 7: Table Of Contents

    Specifications ....129 POLARIS Products ....133 Troubleshooting ....135 Warranty .
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  • Page 9: Introduction

    Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.
  • Page 10 INTRODUCTION SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
  • Page 11 INTRODUCTION DECLARATION OF CONFORMITY Downloaded from ManualsNet.com search engine...
  • Page 12 Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

  • Page 13: Safety

    SAFETY SAFETY TRAINING Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course. For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polaris.com.
  • Page 14 HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.
  • Page 15 If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.
  • Page 16 SAFETY Read the owner’s manual. Never allow anyone under 16 years of age to operate this vehicle. Never use alcohol or drugs before or while driving or riding. This vehicle is approved for on-road operation. Wear approved helmet, goggles, and protective clothing.
  • Page 17 AIR FILTER INTAKE ALERT Use a Polaris approved air filter. The use of a non-Polaris approved air filter may cause engine damage. Before installing filter ensure there is no dirt or debris in the clean side of the intake tube.
  • Page 18 SAFETY HITCH CAPACITY ALERT Read the owner’s manual. MAXIMUM DRAWBAR PULL: 3200 N ON LEVEL GROUND MAXIMUM VERTICAL LOAD: 1700 N Label Location: on the hitch. SAFETY WARNINGS WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death.
  • Page 19 • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident.
  • Page 20 SAFETY • Never modify this vehicle through improper installation or use of non- POLARIS approved accessories. • Always re-install plastics and heat shields after vehicle is serviced. • Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached.
  • Page 21 SAFETY USING ALCOHOL OR DRUGS WARNING Never consume alcohol or drugs before or while operating this vehicle. Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. FAILURE TO INSPECT BEFORE OPERATING WARNING Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
  • Page 22 SAFETY CAB DOORS Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover. Always make sure all cab doors are closed and latched while riding in this vehicle. Cab doors are NOT intended to be used as arm rests.
  • Page 23 SAFETY UNDER ANY OF THESE CONDITIONS: DO ALL OF THESE STEPS: Towing IMPROPER TIRE MAINTENANCE WARNING Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle.
  • Page 24 SAFETY JUMPS AND STUNTS CAUTION Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving. TURNING IMPROPERLY CAUTION Turning improperly could cause loss of traction, loss of control, accident or rollover.
  • Page 25 SAFETY STALLING WHILE CLIMBING A HILL CAUTION Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.
  • Page 26 SAFETY SKIDDING OR SLIDING CAUTION Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.
  • Page 27 SAFETY OPERATING ON FROZEN BODIES OF WATER WARNING Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.
  • Page 28 SAFETY HOT EXHAUST SYSTEMS WARNING Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
  • Page 29 SAFETY EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed.
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  • Page 31: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS Console CV Boot/Rear Caliper Headlights Receiver Hitch Bumper/Brush Guard ROPS Cab Frame Radiator Hip Bar Tailgate Cargo Box Taillights Fuel Cap Downloaded from ManualsNet.com search engine...
  • Page 32 FEATURES AND CONTROLS CONSOLE Steering Wheel Adjustment Lever 3-Mode Throttle Control Switch Instrument Cluster AWD Switch Ignition 12V Auxiliary Outlets Gear Selector (Shifter) Storage Compartment Hazard Switch Fog Light Switch Park Brake Lever STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference.
  • Page 33 PARK. Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer can assist in resolving any shifting problems. NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result.
  • Page 34 FEATURES AND CONTROLS USING LOW GEAR Low gear is the primary driving range for the RANGER. High gear is intended for use on hard-packed surfaces with light loads. Whenever the vehicle is left unattended, always place the transmission in PARK. Always shift into low gear for any of the following conditions.
  • Page 35 FEATURES AND CONTROLS Turn Signal • Move the turn signal lever downward to signal a left turn. The left turn signal lamps in the taillight and below the front headlight will flash. The turn signal indicator in the gauge will also flash. •...
  • Page 36 FEATURES AND CONTROLS POLARIS 3-MODE THROTTLE CONTROL SWITCH The Polaris 3-Mode Throttle Control Switch has three positions: • Performance (PERF) • Standard (STND) • Work (WORK) Always use low gear for any of the following conditions regardless of the selected throttle control setting.
  • Page 37 FEATURES AND CONTROLS AUXILIARY OUTLET The vehicle is equipped with a 12-volt accessory outlet on the dash. Use the outlet to power an auxiliary light or other optional accessories or lights. For service, the dash outlet connection is under the dash. FOOT PEDALS BRAKE PEDAL Depress the brake pedal...
  • Page 38 FEATURES AND CONTROLS THROTTLE PEDAL Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. If the throttle pedal and brake pedal are applied simultaneously, engine power may be limited.
  • Page 39 FEATURES AND CONTROLS SEAT BELTS This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passengers. Always make sure the seat belts are secured for all riders before operating. The driver’s seat belt is equipped with a seat belt interlock.
  • Page 40 FEATURES AND CONTROLS SEAT BELT INSPECTION Inspect all seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2.
  • Page 41 EPS has shut down. Turn the key off and on to reset the unit. If the light remains on after starting the engine, the EPS system is inoperative. See your POLARIS dealer, or other qualified person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.
  • Page 42 FEATURES AND CONTROLS OPENING THE NET 1. To exit the vehicle, release the top front latch. 2. Rotate the net rearward and slide the lower net rod out of the mount to remove it. 3. Allow the net to hang freely outside the vehicle while dismounting. ROLLOVER PROTECTIVE STRUCTURE (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements.
  • Page 43 FEATURES AND CONTROLS HITCH AND TRAILER CONNECTOR (ZUGMASCHINE MODELS ONLY) WARNING Whenever the vehicle is towing, always stay clear of the area between the vehicle and the towed object. REAR HITCH Use the rear hitch for towing a trailer. REAR HITCH SPECIFICATIONS Material S355J2+N Fasteners...
  • Page 44 FEATURES AND CONTROLS HITCH REMOVAL / INSTALLATION 1. To remove the hitch, remove the cotter pin and hitch pin . Remove the hitch, then reinstall the hitch pin and secure the cotter pin 2. To install the hitch, remove the cotter pin from the hitch pin and remove the hitch pin 3.
  • Page 45 FEATURES AND CONTROLS INSTRUMENT CLUSTER NOTICE High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces.
  • Page 46 Steering (EPS) position. If the light remains on, the EPS system is Warning (if inoperative. See your POLARIS dealer, or other qualified equipped) person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.
  • Page 47 FEATURES AND CONTROLS LAMP INDICATES CONDITION Check Battery This warning lamp illuminates if the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied.
  • Page 48 Service A flashing wrench symbol alerts the operator that the preset Indicator service interval has been reached. Your POLARIS dealer, or other qualified person, can provide scheduled maintenance. See page 50 for resetting instructions. Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank.
  • Page 49 FEATURES AND CONTROLS Description Area 1 Modes Engine Temperature Temperature of engine coolant Vehicle Speed Speed of vehicle Tachometer Engine speed (RPM) Description Area 2 Modes Odometer The odometer records and displays the distance traveled by the vehicle. Trip Meters (T1/T2) A trip meter records the distance traveled by the vehicle if reset before each trip.
  • Page 50 FEATURES AND CONTROLS 1. Press and release either toggle button to cycle to the desired option. 2. Press MODE to select the option. 3. Press either toggle button to cycle to the desired setting. 4. Press MODE to save and exit to the settings menu.
  • Page 51 FEATURES AND CONTROLS CLOCK The clock must be reset any time the battery has been disconnected or discharged. 1. Press and hold the MODE button to enter the settings menu. 2. Press either toggle button to cycle to the “CLOCK” option. Press MODE to select.
  • Page 52 FEATURES AND CONTROLS TRIP METER Use a trip meter to track the distance traveled during a specific trip or period of time. Reset the meter to zero before traveling. 1. Press either toggle button to cycle to the desired trip meter option (T1 or T2).
  • Page 53 FEATURES AND CONTROLS ENGINE ERROR CODES The error screen displays only when the CHECK ENGINE indicator is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine.
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  • Page 55: Operation

    OPERATION OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.
  • Page 56 3. Never carry a passenger on this vehicle. 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Never operate with accessories not approved by POLARIS for use on this vehicle. Downloaded from ManualsNet.com...
  • Page 57 OPERATION 6. Operate this vehicle off-road only. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for on-road use). 7. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.
  • Page 58 Indicator lights/switches Ensure proper operation page 32 Intake pre-filters Inspect, clean Headlamps Check operation, apply POLARIS dielectric page 113 grease when lamp is replaced Brake light/tail lamps Check operation Seat Latch Push down on the seat back to ensure the latch...
  • Page 59 OPERATION 6. Turn the ignition key to the START position. Engage the starter for a maximum of five seconds. Release the key when the engine starts. Turn the key to either LIGHTS ON or POSITION LIGHTS ON. LIGHTS ON POSITION LIGHTS ON START 7.
  • Page 60 OPERATION BRAKING 1. Release the throttle pedal completely. CAUTION When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking. 2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls.
  • Page 61 OPERATION HAULING CARGO WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
  • Page 62 OPERATION Loads should be centered on the vehicle and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box. Always read and understand the load distribution warnings listed on warning labels and in this manual.
  • Page 63 OPERATION DUMPING THE CARGO BOX To dump the cargo box, do the following: 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3.
  • Page 64 OPERATION All-Wheel Drive (AWD) Differential Lock (2WD) Differential Unlock (TURF Mode) Press the top of the driveline mode switch to engage All Wheel Drive (AWD). The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction.
  • Page 65 OPERATION 4. Shift into low gear and drive forward. 5. If the front gearcase remains locked after following these instructions, see your dealer or other qualified service person for service. LOCKING THE DIFFERENTIAL Move the switch to the center position to lock the differential and operate in two wheel drive (2WD).
  • Page 66 OPERATION DRIVING PROCEDURES NEW OPERATOR DRIVING PROCEDURES 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Visit www.rohva.org or call 866-267-2751. Hands-on training is also available through ROHVA.
  • Page 67 OPERATION • Avoid sharp turns. • Never turn while applying heavy throttle. • Never make abrupt steering maneuvers. • Operate at speeds appropriate for your skills, the conditions and the terrain. • DO NOT do power slides, “donuts”, jumps or other driving stunts. DRIVING WITH A PASSENGER 1.
  • Page 68 OPERATION When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Follow these precautions when encountering slippery conditions: 1. Do not operate on excessively rough, slippery or loose terrain. 2.
  • Page 69 OPERATION 5. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. 6. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly. 7. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
  • Page 70 OPERATION NOTE If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined in the Spark Arrester section, and take the vehicle in for service at the first opportunity.
  • Page 71 OPERATION PARKING THE VEHICLE To park the vehicle, do the following: 1. Apply the brakes. Stop the vehicle on a level surface. 2. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.
  • Page 72 OPERATION BOARDING AND EXITING THE VEHICLE • Never try to climb onto or exit the vehicle while it is moving. • Do not exit the vehicle by jumping off. • Always face the vehicle when boarding or exiting. • Do not grab controls as hand supports. This may cause inadvertent machine movements.

  • Page 73: Winch Guide

    WINCH GUIDE WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 74 WINCH GUIDE b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to feed and rewind the cable evenly before continuing the winch operation. 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.
  • Page 75 WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 76 WINCH GUIDE 4. Always use the hook strap when handling the hook. WARNING Never put your fingers into the hook. This could lead to SEVERE INJURY. • Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable.
  • Page 77 INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified dealer. • If possible, keep the winch cable aligned with the centerline of the winching vehicle.
  • Page 78 WINCH GUIDE b. Lay the damper on top of the mid-point of the winch cable length that is spooled out. c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.
  • Page 79 WINCH GUIDE 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
  • Page 80 Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.
  • Page 81 WINCH GUIDE SHOCK LOADING WARNING Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.
  • Page 82 3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

  • Page 83: Emission Control Systems

    Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. SPARK ARRESTER Your POLARIS vehicle has a spark arrester that was designed for on-road and off-road operation. It is required that this spark arrester remain installed and functional when the vehicle is operated.
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  • Page 85: Maintenance

    PERIODIC MAINTENANCE Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
  • Page 86 MAINTENANCE MAINTENANCE CHART KEY SYMBOL DESCRIPTION Perform these procedures more often for vehicles subjected to severe use. Have an authorized dealer or other qualified person perform these services. WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death.
  • Page 87 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS HOURS CLNDR (MILES) Engine Breather 800 (500) Inspect; replace as needed 50 H Shift Linkage 800 (500) Inspect, lubricate, adjust 50 H Steering 800 (500) 50 H Lubricate Lubricate and inspect Front / Rear 800 (500) 50 H bushings...
  • Page 88 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS HOURS CLNDR (MILES) Wheel Bearings 1600 (1000) Inspect; replace as needed 100 H 12 M Visually inspect shock seals Shock Seals 100 H Ratcheting Cam 3200 (2000) Check; replace as needed 200 H Chain Tensioner 3200 (2000) Change every two years Brake Fluid...
  • Page 89 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS HOURS CLNDR (MILES) Visually inspect shock seals Shock Seals 100 H 5000 (3125) Inspect; adjust as needed Valve Clearance 150 H Clutches (Drive and Inspect; clean; replace worn 3200 (2000) 200 H 12 M Driven) parts...
  • Page 90 POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil or a similar oil. Refer to the Specifications section for capacities. Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation.
  • Page 91 MAINTENANCE OIL CHECK The oil dipstick is located on the engine. Access the dipstick through the right rear wheel well. To check the oil, do the following: 1. Position vehicle on a level surface and place the transmission in PARK. 2.
  • Page 92 MAINTENANCE ENGINE OIL AND FILTER REPLACEMENT Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil. The engine oil dipstick is located on the right front side of the engine. The engine oil fill cap is located on top of the valve cover.
  • Page 93 MAINTENANCE 8. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase. 9. Lubricate the O-ring on the new oil filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition. Install it to specification. TORQUE Oil Filter: Turn by hand until filter O-ring contacts sealing surface, then turn an additional 3/4 turn.
  • Page 94 MAINTENANCE GEARCASES GEARCASE SPECIFICATION CHART DRAIN PLUG/ FILL PLUG LEVEL GEARCASE LUBRICANT CAPACITY TORQUE CHECK PLUG TORQUE AGL Gearcase Transmission 41 oz. 10-14 ft. lbs. 10-14 ft. lbs. Lubricant & (Main (1200 ml) (14-19 Nm) (14-19 Nm) Transmission Gearcase) Fluid Demand Drive 9.3 oz.
  • Page 95 MAINTENANCE TRANSMISSION OIL CHANGE The drain plug is located on the bottom of the gearcase. Access the drain plug through the hole in the skid plate. 1. Remove the fill plug 2. Place a drain pan under the drain plug 3.
  • Page 96 Refer to the Specifications section for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent. SPARK PLUG GAP/TORQUE ELECTRODE GAP NEW OR USED PLUG TORQUE 0.7 –...
  • Page 97 MAINTENANCE SPARK PLUG INSPECTION Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. CAUTION A hot exhaust system and engine can cause burns.
  • Page 98 ADDING OR CHANGING COOLANT POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.
  • Page 99 But if the overflow bottle has run dry, the level in the radiator should also be inspected. 5. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part. Downloaded from ManualsNet.com...
  • Page 100 MAINTENANCE OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the vehicle on a level surface.
  • Page 101 • See your dealer or other qualified service person as outlined in the owner's manual. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 102 MAINTENANCE 1. Remove the nine fasteners that retain the outer clutch cover. NOTE Removal of left rear wheel or left rear shock is NOT necessary for belt replacement. 2. Pull the clutch cover forward and slide towards the front of the vehicle as shown above.
  • Page 103 MAINTENANCE 6. Insert clutch spreader tool into threaded hole on driven clutch as shown and turn clockwise to spread clutch. NOTE Clutch spreader tool part number 2875911 is found in vehicle tool kit. 7. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle.
  • Page 104 MAINTENANCE 2. Rotate the driven clutch and walk the belt into the clutch. 3. Remove the clutch spreader tool from driven clutch. 4. Rotate / spin the driven clutch and belt approximately 5-7 times to properly seat the belt in the driven clutch. 5.
  • Page 105 MAINTENANCE 8. Install and torque the outer clutch cover bolts to specification. TORQUE PVT Outer Cover Fasteners 35 in-lbs (4 Nm) Downloaded from ManualsNet.com search engine...
  • Page 106 6. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range. 7. Test for belt slippage. If the belt slips, repeat the process. 8. Your vehicle requires service as soon as possible. Your POLARIS dealer can assist. VEHICLE IMMERSION...
  • Page 107 6. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service. 7. If water has been ingested into the PVT follow the procedure for drying.
  • Page 108 MAINTENANCE 4. Inspect the airbox for oil or water deposits. Wipe away any deposits with a clean shop towel. NOTE If the filter has been soaked with fuel or oil it must be replaced. DO NOT attempt to clean the air filter. 5.
  • Page 109 MAINTENANCE SPARK ARRESTER WARNING • Never operate the vehicle without the spark arrester. • Remove any combustible materials from the area. Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.
  • Page 110 MAINTENANCE WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury.
  • Page 111 MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 1. Check the brake system for fluid leaks.
  • Page 112 MAINTENANCE SUSPENSION ADJUSTMENT The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary. 1. Remove the top shock mounting bolts from the inside mounting positions 2. Reposition the shocks to the outside mounting holes 3. Reinstall the shock mounting bolts. Torque to 40 ft-lbs (54.2 Nm).
  • Page 113 Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. Always use POLARIS approved size and type of tires for this vehicle when replacing tires.
  • Page 114 MAINTENANCE WHEEL REMOVAL 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. Stop the engine. 3. Loosen the wheel nuts slightly. 4. Elevate the side of the vehicle by placing a suitable stand under the frame. 5.
  • Page 115 MAINTENANCE LIGHTS Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility.
  • Page 116 MAINTENANCE 3. Disconnect the harness from the bulb. Be sure to pull on the connector, not on the wiring. 4. Remove the rubber bulb cover, release the bulb protection spring remove the bulb from the headlight housing. 5. Install the new bulb into the housing. NOTE Make sure the tab on the bulb locates properly in the housing.
  • Page 117 MAINTENANCE HEADLIGHT BEAM ADJUSTMENT To adjust the headlight beam, do the following: 1. Place the vehicle on a level surface with the headlight approximately 7.6 m ( 25 ft) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 118 MAINTENANCE FUSES If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Raise the passenger seat to access the fuses.
  • Page 119 MAINTENANCE Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels.
  • Page 120 MAINTENANCE The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery. The single most important thing about maintaining a sealed battery is to keep it fully charged.
  • Page 121 If you do not drive the vehicle for more than TWO WEEKS, Polaris recommends using a BatteryMINDer® 1510 1.5 AMP (PN 2830404) or 12V 1.5 AMP Convertible BatteryMINDer®...
  • Page 122 MAINTENANCE BATTERY INSTALLATION 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. Coat the terminals with dielectric grease or petroleum jelly. 4. Connect and tighten the red (positive) cable first. 5. Connect and tighten the black (negative) cable last. 6.
  • Page 123 MAINTENANCE Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a predetermined point.
  • Page 124 Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.
  • Page 125 Replacement safety labels are provided by POLARIS at no charge. POLISHING THE VEHICLE POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. POLISHING TIPS • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 126 STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 127 6. Reinstall the spark plug caps. 7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. STORAGE AREA / COVERS Be sure the storage area is well ventilated.
  • Page 128 MAINTENANCE 4. Check all the points listed in the Daily Pre-Ride Inspection. Tightness of the bolts, nuts and other fasteners should be checked by an authorized dealer or other qualified service facility. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart. TRANSPORTING THE VEHICLE Follow these procedures when transporting the vehicle.
  • Page 129 MAINTENANCE REAR TIE-DOWN LOCATION Rear tie-down points TOWING A RANGER Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed with all four wheels off the ground. Downloaded from ManualsNet.com search engine...
  • Page 130 MAINTENANCE If towing a disabled vehicle is unavoidable, place the disabled vehicle’s transmission in neutral. Tow the shortest distance possible. Do not operate faster than 16 km/h (10 MPH). Downloaded from ManualsNet.com search engine...

  • Page 131: Specifications

    SPECIFICATIONS SPECIFICATIONS RANGER XP 1000 / 1000 ZUG Maximum Weight Capacity (includes weight of operator, 738 kg (1627 lbs.) passenger, cargo, accessories) Dry Weight 714 kg (1574 lbs.) Test GVW - Rollover Protection System 1542 kg (3400 lbs.) per OSHA 29 CFR 1928.53 (ROPS) Fuel Capacity 43.9 l (11.6 gal)
  • Page 132 SPECIFICATIONS RANGER XP 1000 / 1000 ZUG Compression Ratio 10.8:1 Starting System Electric Fuel System Electronic Fuel Injection ECU Controlled Ignition Timing 32° +/- 2° @ 5000 RPM Spark Plug/ Gap MR7F / 0.7-0.8 mm Lubrication System Wet Sump Cooling Liquid Front Suspension Dual A-Arm, IRS 27.94 cm (11.0 in) Travel...
  • Page 133 SPECIFICATIONS RANGER XP 1000 / 1000 ZUG Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) A - Weighted Sound 77.8 dB(A) Pressure at Rider’s Ear C- Weighted Sound 91.1 dB(C) Pressure Level Weighted Sound Power N / A Level CARBON DIOXIDE EMISSIONS CO₂...
  • Page 134 Downloaded from ManualsNet.com search engine...

  • Page 135: Polaris Products

    12 oz bottle (12) Carbon Clean 2871326 16 oz (12) 2870652 Fuel Stabilizer 2.5 gal (2) 2872280 DOT 4 Brake Fluid — 2872189 Loctite™ 565 Thread Sealant — 2871956 POLARIS Battery Tender™ — 2859044 Charger Downloaded from ManualsNet.com search engine...
  • Page 136 Downloaded from ManualsNet.com search engine...

  • Page 137: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR/BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall Use low range during loading. trailer in high range Starting out going up a steep Use low range. incline Driving at low RPM or ground Drive at a higher speed or use low range more frequently. speed (3-7 MPH) Warm the engine at least 5 minutes.
  • Page 138 TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box Inspect, clean, reinstall connectors connections ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE...
  • Page 139 TROUBLESHOOTING ENGINE BACKFIRES POSSIBLE CAUSE SOLUTION Weak spark from spark plug Inspect, clean and/or replace spark plug Incorrect spark plug gap or Set gap to specs or replace plug heat range Old or non-recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug Your authorized dealer can assist wires...
  • Page 140 TROUBLESHOOTING ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug Your authorized dealer can assist wires Incorrect spark plug gap or Set gap to specs or replace plug heat range Loose ignition connections Check all connections and tighten...
  • Page 141 TROUBLESHOOTING ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel Kinked or plugged fuel vent Inspect and replace line Water is present in fuel Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug Your authorized dealer can assist wires...
  • Page 142 Downloaded from ManualsNet.com search engine...

  • Page 143: Warranty

    This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
  • Page 144 WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 145 MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
  • Page 146 IF YOU PURCHASE FROM A PRIVATE PARTY: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
  • Page 147 IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.
  • Page 148 Downloaded from ManualsNet.com search engine...

  • Page 149: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS Downloaded from ManualsNet.com search engine...
  • Page 150 Downloaded from ManualsNet.com search engine...
  • Page 151 7-Way Trailer Connector ..... 42 Clean the Exterior ....124 Clothing........12 Clutch Cover Alert ..... 15 Cold Weather Operation....57 Component Locations....29 Adding or Changing Coolant ..96 Console........30 Age Restrictions ......18 Conventional Battery ....117 AGM Battery Maintenance and Cooling System......
  • Page 152 Engine Runs Irregularly, Stalls Hitch ........41 or Misfires ......138 Hitch Capacity Alert ....16 Engine Stopping......57 Hitch Removal / Installation..42 Engine Stops or Loses Power ..139 Hood Latches ......40 Engine Turns Over, Fails to Hot Exhaust Systems ....
  • Page 153 Signal Words ......8 Periodic Maintenance Table ..83 Spark Arrester ....81, 107 Plugs, Spark......94 Spark Plug Gap/Torque....94 Polaris Products ...... 133 Spark Plug Inspection....95 POLARIS Variable Spark Plug Recommendations ..94 Transmission (PVT) Drying ..104 Specifications ......
  • Page 154 Towing a RANGER ....127 Towing Loads ......60 Trail Etiquette ......54 Trailer Connector....... 41 Trailer Hitch Bracket....40 Transmission Oil Change .... 93 Transmission Oil Check ....92 Transporting the Vehicle.... 126 Turn Signal Lever ...... 32 Turning Improperly..... 22 Unauthorized Use of the Vehicle ...
  • Page 155 Downloaded from ManualsNet.com search engine...
  • Page 156 For your nearest Polaris dealer, visit www.polaris.com Polaris Sales Europe Sarl Place de l’Industrie 2 1180 Rolle, Switzerland Part No. 9930867 Rev 01...

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