Polaris RANGER 1000 2021 Manuals

Manuals and User Guides for Polaris RANGER 1000 2021. We have 1 Polaris RANGER 1000 2021 manual available for free PDF download: Service Manual

Polaris RANGER 1000 2021 Service Manual

Polaris RANGER 1000 2021 Service Manual (610 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 20.13 MB

Table of Contents

Chapter 1 1 General Information

9
- Table of Contents
  9
- Reference Information
  11
- Service Rules
  11
- Publication Part Numbers
  12
- Replacement Keys
  13
- Special Tools Website
  14
- Special Tools Index
  15
- Master Torque List
  19
- Vehicle Identification
  26
- Vehicle Specifications
  27
  - Model Specifications - 3 Seat
    27
  - Model Specifications - Crew
    31
- General Diagnostics Information Overview
  35
- Guided Symptom Diagnostic
  35
- Guided Symptom References
  36
- Engine and Drivability Diagnostic Procedures
  37
  - Engine Cranks but Does Not Start
    40
  - Crank no Start or Slow Crank
    42
  - Over Heating
    43
  - Warning Lights
    44
  - Engine Troubleshooting
    45
  - Cooling Troubleshooting
    47
- Digital Wrench
  48
- Polaris Mobile Digital Wrench® (Pmdw)
  53
- Engine Electrical Diagnostics
  54
- Fluid Inspection
  67
- Fluid Leaks
  67
- Fuel System Diagnostics
  68
  - Fuel System Troubleshooting
    68
- Pvt System Diagnostics
  70
  - Pvt System Troubleshooting
    70
  - Pvt System Overheating / Diagnosis
    72
- Transmission Diagnostics
  73
  - Hard Shifting
    73
  - Transmission Isolation
    73
- Final Drive Diagnostics
  74
  - All Wheel Drive (Awd) Concerns
    74
  - Driveshaft (Half Shaft) Diagnostics
    74
- Brake System Diagnostics
  75
  - Brake Noise Troubleshooting
    75
  - Brake Vibration
    75
  - Caliper Overheats (Brakes Drag)
    76
  - Poor Brake Performance
    76
  - Brakes Lock
    76
- Steering / Suspension Diagnostics
  77
- Electrical Diagnostics
  81
Maintenance Chapter 2 Maintenance 2

89
- Chapter 2
  91
- General Information - Maintenance
  91
- Maintenance
  91
- Service Notes - Maintenance
  91
- Maintenance Specifications
  92
- Service Products
  93
- Periodic Maintenance
  94
  - Periodic Maintenance Overview
    94
  - Break-In Period
    94
  - Pre-Ride Inspection
    95
  - Maintenance Intervals
    96
  - Maintenance Quick Reference
    116
  - Grease Lubrication Points
    118
- Engine Maintenance
  119
  - Engine Oil Level Inspection
    119
  - Engine Oil and Filter Service
    120
  - Valve Clearance Inspection
    121
  - Cam Chain Tensioner Inspection
    122
- Cooling System Maintenance
  124
  - Liquid Cooling System Overview
    124
  - Coolant Strength / Type
    124
  - Coolant Level Inspection
    125
  - Cooling System Hose Inspection
    126
  - Radiator Inspection
    126
  - Coolant Replacement
    126
- Air Intake and Exhaust Maintenance
  127
  - Air Filter Service
    127
  - Engine Crankcase Breather Hose Inspection
    128
  - Exhaust Spark Arrestor Inspection
    129
  - Exhaust Heat Shield Inspection
    130
- Fuel System Maintenance
  131
  - Fuel Line Inspection
    131
  - Fuel Pump / Filter Inspection
    131
  - Fuel Tank Vent Line Inspection
    132
- Pvt System Maintenance
  133
  - Drive Belt Inspection
    133
  - Pvt System Drying
    133
- Transmission and Front Gearcase Maintenance
  134
  - Transmission Fluid Level Inspection
    134
  - Transmission Fluid Replacement
    134
  - Shift Cable Inspection
    135
  - Shift Cable Adjustment
    135
  - Front Gearcase Fluid Level Inspection
    137
  - Front Gearcase Fluid Replacement
    138
- Final Drive Maintenance
  140
  - Drive Shaft Boot Inspection
    140
  - Wheel Service
    140
  - Tire Inspection
    141
  - Tire Pressure Inspection
    141
- Steering Maintenance
  142
  - Steering System Inspection
    142
  - Steering Wheel Free-Play Inspection
    142
  - Tie Rod End Inspection
    143
  - Wheel Toe Measurement
    143
  - Wheel Toe Adjustment
    144
- Suspension Maintenance
  145
  - Suspension Inspection
    145
  - Spring Pre-Load Adjustment
    145
- Brake System Maintenance
  146
  - Brake Fluid Level Inspection
    146
  - Brake Fluid Replacement / Brake Bleeding
    146
  - Brake Pad Inspection
    148
  - Brake Disc Inspection
    148
  - Brake Hose and Fitting Inspection
    148
- Electrical Maintenance
  149
  - Battery Maintenance
    149
    
    Lead Acid Conventional Battery Maintenance
    149
    
    Dry Shipped Agm Battery Maintenance
    149
    
    Lead Acid Low Maintenance Battery Maintenance
    149
    
    Agm Low Maintenance Battery Maintenance
    149
  - Battery Service
    150
  - Chassis / Engine Electrical Ground
    152
  - Throttle Pedal Inspection
    152
Chapter 3 Engine / Cooling / Exhaust

153
- Engine Service Specifications
  155
- Engine Specifications
  155
- Engine Torque Sequences
  157
- Valve Lash - Tappet Selection
  159
- Bearing Selection Identification Letters and Numbers
  160
- Connecting Rod Bearing Selection
  161
- Crankshaft Main Bearing Selection
  161
- Intake Service
  162
  - Intake System Assembly View
    162
  - Airbox Service
    163
  - Intake Duct Service
    164
  - Throttle Body Service
    167
  - Intake Manifold Service
    168
  - Intake Manifold Adapter Service
    170
- Exhaust Service
  171
  - Exhaust System Assembly View
    171
  - Muffler Service
    172
  - Headpipe Service
    174
- Engine Service
  176
  - Accessible Engine Components
    176
  - Engine Mount Isolator Service
    176
  - Crankshaft Pto Seal Replacement
    178
  - Engine Removal & Installation
    179
  - Engine Timing
    184
- Engine Service - Top End
  187
  - Valve Cover Service
    187
  - Valve Clearance Adjustment
    188
  - Cam Chain Tensioner Service
    189
  - Camshaft Sprocket Service
    190
  - Camshaft Service
    191
  - Camshaft Inspection
    192
  - Cylinder Head Removal and Installation
    193
  - Valve Service
    196
  - Valve Inspection
    198
  - Valve Seat Reconditioning
    199
  - Cylinder Head Inspection
    201
  - Combustion Chamber Cleaning
    201
- Engine Service - Bottom End
  202
  - Oil Filter Adapter Service
    202
  - Oil Sump Service
    203
  - Oil Pump Service
    204
  - Upper Crankcase Service
    206
  - Balance Shaft Service
    209
  - Crankshaft Service / Inspection
    210
  - Cylinder / Piston Service
    214
  - Crankcase Inspection
    216
  - Cylinder Inspection
    217
  - Piston Disassembly / Inspection
    218
  - Connecting Rod Inspection
    221
  - Stator Cover Service
    222
  - Flywheel Service
    224
  - Starter One-Way Clutch Service
    225
  - Starter One-Way Clutch Inspection
    227
- Cooling System Service
  228
  - Cooling System Specifications
    228
  - Cooling System Assembly View
    229
  - Coolant Service
    232
  - Cooling System Pressure Test
    233
  - Radiator Cap Pressure Test
    234
  - Radiator Service
    234
  - Radiator Fan Removal
    236
  - Engine Oil Cooler Service
    237
  - Thermostat Replacement
    238
  - Water Pump Service
    239
  - Heater Valve Service
    244
- Troubleshooting
  245
  - Oil Pressure Test
    245
  - Engine Cylinder Leakdown Test
    245
Chapter 4 Engine Electrical

247
- Engine Harness
  249
- Electronic Control Unit (Ecu)
  254
  - Ecu Operation Overview
    254
  - Ecu Service
    254
  - Ecu Replacement
    255
- Crankshaft Position Sensor (Cps)
  256
  - Cps Operation Overview
    256
  - Cps Test
    256
  - Cps Replacement
    257
- Electronic Throttle Control (Etc)
  258
  - Etc Operation Overview
    258
  - Etc Test
    258
  - Etc Replacement
    258
  - Etc Learn Procedure
    258
- Starter System Service
  259
  - Starter Solenoid Operation
    259
  - Starter Solenoid Bench Test
    260
  - Starter Motor Service
    260
  - Starting System Testing Flow Chart
    262
  - Voltage Drop Test
    263
  - Troubleshooting
    263
- Ignition System Service
  264
  - Ignition Coil
    264
    
    Ignition Coil Operation Overview
    264
    
    Ignition Coil Service
    264
  - Spark Plug
    266
    
    Spark Plug Inspection
    266
    
    Spark Plug Service
    266
  - Ignition System Testing
    268
- Temp / Manifold Absolute Pressure Sensor (T-Map)
  269
  - Tmap Operation Overview
    269
  - T-Map Sensor Replacement
    269
  - T-Map Sensor Test
    269
- Engine Coolant Temperature Sensor (Ect)
  270
  - Ect Operation Overview
    270
  - Ect Sensor Replacement
    270
  - Ect Resistance Values
    271
  - Ect Sensor Test
    272
- Engine Electrical
  273
  - Oxygen Sensor Service
    273
  - Oxygen Sensor Diagnostic Tips
    274
- Oxygen Sensor
  273
  - Oxygen Sensor Information
    273
- Drive Mode Switch
  276
  - Drive Mode Switch Description and Operation
    276
  - Drive Mode Switch Replacement
    276
- Accelerator Position Sensor (Aps)
  277
  - Aps Operation Overview
    277
  - Aps Replacement
    277
  - Aps Test
    277
- Cooling System Testing
  278
Chapter 5 Fuel System

281
- Fuel System Specifications
  282
- General Information - Fuel System
  282
- Service Notes - Fuel System
  282
- Electronic Fuel Injection
  283
  - Fuel System Operation Overview
    283
  - Initial Priming / Starting Procedure
    283
  - Fuel System Components
    283
  - Fuel System Component Locations
    284
- Fuel Lines
  285
  - Fuel Line Routing
    285
  - Fuel Line Quick Connect Removal
    286
  - Fuel Supply Line Service
    288
  - Vent Line Termination Fitting
    289
  - Fuel Vent Line Routing
    290
  - Fuel Vent Line Routing (Evap Models)
    291
- Fuel Tank
  292
  - Fuel Tank Assembly View
    292
  - Fuel Tank Service
    293
- Fuel Pump
  296
  - Operation Overview
    296
  - Fuel Sender Test
    296
  - Fuel Pressure Test
    297
  - Fuel Pump Replacement
    299
- Evap System
  302
  - Carbon Canister Service
    302
  - Purge Valve Service
    303
- Fuel Injector
  304
  - Fuel Injector Operation Overview
    304
  - Fuel Injector Troubleshooting
    304
  - Fuel Injector Test
    305
  - Fuel Injector Service
    305
Chapter 6 Pvt System

309
- Clutch Settings
  310
- General Information - Pvt System
  310
- Pvt Specifications
  310
- Pvt System Overview
  311
  - Drive Clutch Operation
    311
  - Driven Clutch Operation
    311
  - Pvt Break-In (Drive Belt / Clutches)
    311
  - Maintenance / Inspection
    311
- Drive Belt
  312
  - Drive Belt Service
    312
  - Driven Clutch Alignment
    313
- Pvt System Service
  314
  - Pvt Covers and Ducting Assembly View
    314
  - Pvt Clutch Cover Service
    315
  - Drive Clutch Removal / Installation
    317
  - Driven Clutch Removal / Installation
    318
  - Inner Pvt Cover Service
    319
- Drive Clutch Service
  322
  - Drive Clutch Assembly View
    322
  - Drive Clutch Service
    323
  - Drive Clutch Inspection
    325
  - Roller Replacement
    327
  - Bushing Service
    328
- Driven Clutch Service
  330
  - Driven Clutch Assembly View
    330
  - Driven Clutch Service
    331
  - Helix and Movable Sheave Bushing Inspection
    333
  - Bushing Service
    334
- Vehicle Creeping
  335
Chapter 7 Transmission

337
- General Information - Transmission
  338
- Service Notes - Transmission
  338
- Special Tools - Transmission
  338
- Transmission Specifications
  338
- Shift Cable
  339
  - Shift Lever Removal / Installation
    339
  - Shift Cable Inspection
    339
  - Shift Cable Adjustment
    340
  - Shift Cable Routing
    343
  - Shift Cable Service
    345
- Transmission Service
  350
  - Transmission Assembly View
    350
  - Transmission Vent Line Routing
    351
  - Transmission Removal and Installation
    352
  - Transmission Disassembly
    356
  - Differential Operation
    359
  - Bevel Differential Disassembly
    362
  - Bevel Differential Assembly
    363
  - Gear, Shaft, Bearing Inspection
    365
  - Snorkel Gear Backlash Procedure
    366
  - Transmission Assembly
    368
Chapter 8 Final Drive

375
- Final Drive Specifications (2020)
  377
- Final Drive Specifications (2021+)
  377
- General Information - Final Drive
  377
- Service Notes - Final Drive
  377
- Rear Hub Identification
  378
- Front Bearing Carrier Service
  379
  - Bearing Carrier Removal / Inspection
    379
  - Bearing Replacement
    381
  - Bearing Carrier Installation
    382
- Prop Shaft Service
  385
  - Front Prop Shaft Service (Crew)
    386
  - Rear Prop Shaft Service (Crew)
    388
- Propshaft U-Joint Service
  390
  - Propshaft U-Joint Disassembly
    390
  - Propshaft U-Joint Assembly
    391
- Front Gearcase Service 2020 Models
  393
  - Front Gearcase Assembly View
    393
  - Front Gearcase Removal
    394
  - Front Gearcase Disassembly / Inspection
    395
  - Front Gearcase Assembly
    398
  - Front Gearcase Installation
    400
- Front Gearcase Service 2021+ Models
  402
  - Front Gearcase Assembly View
    402
  - Front Gearcase Removal
    403
  - Front Gearcase Disassembly (Non-Adc)
    405
  - Front Gearcase Inspection
    408
  - Front Gearcase Assembly (Non-Adc)
    410
  - Front Gearcase Installation
    413
  - Front Gearcase Vent Line Routing
    416
- Front Drive Operation / Troublehsooting
  417
  - All Wheel Drive (Awd) Operation
    417
  - All Wheel Drive (Awd) Diagnosis
    418
- Rear Bearing Carrier Service
  420
- Rear Drive Shaft Service
  424
  - Rear Drive Shaft Removal
    424
  - Rear Drive Shaft Installation
    425
Chapter 9 Steering / Suspension

433
- General Information - Steering / Suspension
  434
- Service Notes - Steering / Suspension
  434
- Steering & Suspension Specifications
  434
- Steering & Suspension Assembly Views
  435
  - Steering Assembly View
    435
  - Front Suspension Assembly View
    436
  - Rear Suspension Assembly View
    438
- Steering Assembly Service
  439
  - Steering Wheel / Upper Steering Shaft Removal
    439
  - Steering Rack Removal
    440
  - Steering Rack Installation
    440
  - Power Steering Unit Installation
    442
  - Steering Inspection
    443
  - Tie Rod End / Wheel Hub Inspection
    444
  - Wheel Toe Measurement
    444
  - Wheel Toe Adjustment
    445
- Front A-Arm Service
  446
  - Front Lower A-Arm Removal / Installation
    446
  - A-Arm Bushing Replacement
    447
- Ball Joint Service
  449
  - Ball Joint Service Preparation
    449
  - Ball Joint Removal
    449
  - Ball Joint Installation
    450
- Rear A-Arm Service
  452
  - Rear Upper A-Arm Removal
    452
  - Rear Upper A-Arm Installation
    453
  - A-Arm Bushing Replacement
    454
  - Rear Lower A-Arm Removal
    454
  - Rear Lower A-Arm Installation
    455
- Stabilizer Bar Service
  455
- Shock / Spring Service
  456
  - Shock Analysis
    456
  - Shock Removal and Installation
    457
  - Shock Spring Replacement
    458
Chapter 10 Brake System

459
- General Information - Brake System
  460
- Service Notes - Brake System
  460
- Brake System Specifications
  461
- Brake System Service
  462
  - Brake System Assembly View
    462
  - Brake Line Routing
    463
  - Brake Line Clocking
    465
  - Brake Fluid Replacement / Brake Bleeding
    468
- Master Cylinder Service
  470
  - Master Cylinder Removal
    470
  - Master Cylinder Installation
    471
- Brake Pedal Replacement
  471
- Front Brake Pad Service
  472
  - Front Brake Pad Removal
    472
  - Front Brake Pad Inspection
    472
  - Front Brake Pad Installation
    473
  - Brake Burnishing Procedure
    474
- Front Caliper Service
  475
  - Front Caliper Assembly View
    475
  - Front Caliper Removal
    476
  - Front Caliper Disassembly
    477
  - Front Caliper Inspection
    478
  - Front Caliper Assembly
    478
  - Front Caliper Installation
    479
- Rear Brake Pad Service
  480
  - Rear Brake Pad Removal
    480
  - Rear Brake Pad Inspection
    481
  - Rear Brake Pad Installation
    481
  - Brake Burnishing Procedure
    481
- Rear Caliper Service
  482
  - Rear Caliper Assembly View
    482
  - Rear Caliper Removal
    483
  - Rear Caliper Disassembly
    484
  - Rear Caliper Inspection
    484
  - Rear Caliper Assembly
    485
  - Rear Caliper Installation
    485
- Brake Disc Service
  486
  - Brake Disk Inspection
    486
  - Disc Runout
    487
  - Brake Disc Replacement
    487
Chapter 11 Body / Frame

489
- General Information - Body / Frame
  491
- Body Assembly Views
  492
  - Chassis Assembly View
    492
  - Chassis Assembly View (Crew)
    493
  - Rops Assembly View
    494
  - Rops Assembly View (Crew)
    496
  - Dash Panel Assembly View
    498
  - Front Body Assembly View
    499
  - Floors and Bulkhead Assembly View
    500
  - Roof Assembly View
    502
  - Rear Panel Assembly View
    503
  - Cargo Box Assembly View
    504
- Cab Frame Service
  507
  - Windshield Service
    507
  - Tip-Out Windshield Service
    508
  - Tip-Out Windshield Adjustment
    509
  - Roof Service
    510
  - Headliner Service
    513
  - Headliner Service (Crew)
    513
- Exterior Body Service
  519
  - Front Bumper Service
    519
  - Front Fender Service
    520
  - Skid Plate Service
    523
  - Front Fascia Service
    524
  - Side Bezel Cover Service
    526
  - Side Bezel Service
    527
  - Rocker Panel Service
    529
  - Rear Close-Off Panel Service
    531
  - Decal Replacement
    533
- Cargo Box
  536
  - Cargo Box Service
    536
- Door Service
  538
  - Standard Door Panel Service
    538
  - Door Latch Service
    541
  - Window Regulator / Door Glass Service
    541
  - Door Removal / Installation
    544
- Interior Body Service
  545
  - Upper Dash Panel Service
    545
  - Lower Dash Panel Service
    547
- Seat Back Service
  550
- Floor Panel Service
  551
- Lower Seat Base Removal
  551
- Roof Removal / Installation
  552
- Rear Panel Removal / Installation
  553
- Accessory Service
  554
Chapter 12 Chassis / Body Electrical

555
- General Information - Electrical System
  557
- Service Notes - Electrical
  557
- Body Electrical Specifications
  558
- Fuse Box / Circuit Protection
  559
  - Fuse Box Breakout
    559
  - Relay Operation
    561
- Vehicle Harness Service
  563
  - Chassis Harness Routing
    563
  - Chassis Harness Removal
    570
  - Chassis Harness Installation
    570
- Switches / Controls Service
  571
  - Transmission (Gear Position) Switch
    572
  - Seat Belt Switch
    572
  - Brake Pedal Switch Inspection
    573
  - All Wheel Drive Circuit Service
    573
    
    Awd / 2Wd / Turf Switch
    573
    
    Operation Overview
    573
    
    Diagnosing System Failures
    573
  - Vehicle Speed Sensor Service
    574
    
    Speed Sensor Location
    574
    
    Speed Sensor Testing
    575
  - Rear Diff Solenoid Service
    575
    
    Differential Solenoid Overview
    575
    
    Differential Solenoid Circuit Operation
    575
    
    Differential Solenoid Replacement
    576
- Instrument Cluster Service
  577
  - Instrument Cluster Pinouts
    577
- Charging System Service
  578
  - Stator
    578
    
    Stator Inspection
    578
    
    Stator Service
    578
    
    Regulator / Rectifier Replacement
    580
    
    Charging System Testing Flow Chart
    580
  - Charging System Troubleshooting Charging System "Break Even" Test
    582
    
    Charging System Stator (Alternator) Tests
    582
    
    Regulator Testing (900 Watt)
    583
- Battery Service
  584
  - Battery Specifications
    584
  - General Battery Information
    584
  - Battery Terminal Block
    584
  - Battery off Season Storage
    585
  - Battery Identification
    585
  - Lead Acid Conventional Battery
    585
    
    Lead Acid Conventional Battery Activation
    585
    
    Lead Acid Conventional Battery Inspection
    586
    
    Lead Acid Conventional Battery Charging and Testing
    586
    
    Lead Acid Conventional Battery Maintenance
    587
  - Dry Shipped Agm Battery
    587
    
    Dry Shipped Agm Battery Activation
    587
    
    Dry Shipped Agm Battery Charging and Testing
    589
    
    Dry Shipped Agm Battery Maintenance
    590
  - Lead Acid Low Maintenance Battery
    591
    
    Lead Acid Low Maintenance Battery Charging and Testing
    591
    
    Lead Acid Low Maintenance Battery Maintenance
    591
  - Agm Low Maintenance Battery
    592
    
    Agm Low Maintenance Battery Charging
    592
    
    Agm Battery Charging - Low Charge
    592
    
    Agm Battery Charging - Deeply Discharged (below 3 Volts)
    593
    
    Agm Low Maintenance Battery Testing
    593
    
    Agm Low Maintenance Battery Maintenance
    594
  - Battery Testing
    594
    
    Battery Conductance Analyzer
    594
    
    Battery Open Circuit Voltage Test (Ocv)
    595
    
    Battery Load Test
    595
    
    Battery Specific Gravity Test
    596
  - Battery Charging Procedure
    596
- Electronic Power Steering (Eps)
  597
  - Eps Operation
    597
- Lighting System Service
  598
  - Headlamp Switch
    598
  - Headlight Adjustment
    599
  - Headlight Bulb Replacement
    601
  - Headlight Housing Service
    601
  - Tail Light Service
    602

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