Polaris RANGER XP 900 (CA) 2013 Manuals

Manuals and User Guides for Polaris RANGER XP 900 (CA) 2013. We have 1 Polaris RANGER XP 900 (CA) 2013 manual available for free PDF download: Manual

Polaris RANGER XP 900 (CA) 2013 Manual

Polaris RANGER XP 900 (CA) 2013 Manual (447 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 70.65 MB

Table of Contents

Chapter 1 1 General Information

4
Maintenance Chapter 2 Maintenance 2

18
- Break-In Period
  20
- Maintenance
  20
- Maintenance Chart Key
  20
- Periodic Maintenance Chart
  20
- Periodic Maintenance Overview
  20
- Pre-Ride - 50 Hour Maintenance Interval
  21
- 50 - 500 Hour Maintenance Interval
  22
- Maintenance Quick Reference
  23
- Grease Lubrication Points
  25
- Polaris Lubricants, Maintenance and Service Products
  28
- Service Products and Lubricants
  28
- Frame, Nuts, Bolts, and Fasteners
  29
- General Vehicle Inspection and Maintenance
  29
- Pre-Ride / Daily Inspection
  29
- Shift Cable Inspection / Adjustment
  29
- Fuel Lines
  31
- Fuel Pump / Fuel Filters
  31
- Fuel System and Air Intake
  31
- Fuel System Warning
  31
- Engine Intake Pre-Filter Screen Service
  32
- Vent Line
  32
- Air Filter Service
  33
- Engine Air Intake Exploded View
  34
- Engine
  35
- Engine Oil and Filter Change
  35
- Engine Oil Level
  35
- Engine Crankcase Breather Hose Inspection
  37
- Engine Cylinder Leakdown Test
  37
- Valve Clearance Inspection
  37
- Exhaust - Spark Arrestor
  39
- Specification Chart
  41
- Transmission and Front Gearcase
  41
- Transmission Lubrication
  41
- Front Gearcase Lubrication
  42
- Coolant Level Inspection
  44
- Coolant Strength / Type
  44
- Cooling System
  44
- Liquid Cooling System Overview
  44
- Cooling System Hoses
  45
- Coolant Drain / Fill
  46
- Radiator Inspection / Cleaning
  46
- Drive Clutch / Driven Clutch / Belt Service
  47
- Pvt / Final Drive / Wheel and Tire
  47
- Pvt Drying
  47
- Pvt Intake Pre-Filter Service
  47
- Drive Shaft Boot Inspection
  48
- Wheel and Hub Torque Table
  48
- Wheel Installation
  48
- Wheel Removal
  48
- Tire Inspection
  49
- Tire Pressure
  49
- Battery Charging / off Season Storage
  50
- Battery Installation
  50
- Battery Maintenance
  50
- Battery Removal
  50
- Electrical and Ignition System
  50
- Chassis / Engine Electrical Ground
  51
- Spark Plug Service
  51
- Steering
  53
- Steering Inspection
  53
- Tie Rod End / Wheel Hub Inspection
  53
- Wheel Toe Adjustment
  54
- Wheel Toe Alignment Inspection
  54
- Shock Position Adjustment
  56
- Spring Pre-Load Adjustment
  56
- Suspension
  56
- Suspension Inspection
  56
- Brake Fluid Inspection
  57
- Brake Hose and Fitting Inspection
  57
- Brake Pad / Disc Inspection
  57
- Brake System
  57
Chapter 3 Engine

58
- General Information
  61
- Special Tools
  61
- Engine Lubrication Specifications
  62
- Oil Pressure Test
  62
- Engine Oil Flow Chart
  64
- Engine Service Specifications
  65
- Engine Specifications
  65
- Engine Detail - Torque Values / Sequences / Assembly Notes
  67
- Main Engine Components - Torque Specification and Sequence
  67
- Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
  68
- Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
  69
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
  70
- Spark Plugs / Starter / Thermostat Housing / Trans Joint / Valve Cover
  71
- Engine Exhaust System
  72
- Exhaust Removal / Installation
  72
- Cooling System Pressure Test
  73
- Engine Cooling System
  73
- Radiator Cap Pressure Test
  73
- Radiator Fan Removal
  74
- Radiator Removal / Coolant Drain
  74
- Thermostat Replacement
  75
- Cooling System Exploded View
  77
- Cooling System Bleeding Procedure
  78
- Water Pump Removal
  78
- Water Pump Installation
  79
- Water Pump Service
  80
- Accessible Engine Components
  84
- Engine Removal
  84
- Engine Service
  84
- Engine Installation
  87
- Engine Mounting and Torque Values
  91
- Engine Break-In Period
  92
- Engine Lubrication Specifications
  92
- Camshaft Removal
  93
- Engine Disassembly / Inspection - Top End
  93
- Valve Cover Removal
  93
- Camshaft / Camshaft Bore Inspection
  95
- Camshaft Sprocket Inspection
  95
- Cylinder Head Inspection
  97
- Cylinder Head Removal
  97
- Cylinder Head Warp Inspection
  97
- Cylinder Head Disassembly
  98
- Valve Inspection
  98
- Combustion Chamber Cleaning
  100
- Valve Seat Reconditioning
  100
- Engine Disassembly / Inspection - Lower End
  103
- Stator Cover Removal / Inspection
  103
- Flywheel Removal
  104
- Water Pump Housing Removal
  104
- Starter One-Way Clutch Disassembly
  105
- Starter One-Way Clutch Assembly
  106
- Crankcase Disassembly
  107
- Balance Shaft Removal / Inspection
  109
- Crankshaft Removal / Inspection
  110
- Crankcase Inspection
  113
- Cylinder / Piston Removal
  113
- Cylinder Inspection
  114
- Piston Disassembly / Inspection
  115
- Piston Ring Removal
  116
- Piston Ring Installed Gap
  117
- Piston Ring to Groove Clearance Inspection
  117
- Connecting Rod Inspection
  118
- Piston-To-Cylinder Clearance
  118
- Bearing Selection Identification Letters and Numbers
  120
- Engine Assembly - Lower End
  120
- Connecting Rod Bearing Selection
  121
- Crankshaft Main Bearing Selection
  121
- Piston Ring Installation
  122
- Upper Crankcase Preparation
  122
- Piston / Connecting Rod Assembly
  123
- Cylinder / Piston Installation
  124
- Crankshaft Installation
  125
- Balance Shaft Installation
  126
- Crankcase Assembly
  127
- Lower Crankcase Preparation
  127
- Flywheel Installation
  131
- Stator Cover Installation
  132
- Cylinder Head Assembly
  133
- Engine Assembly - Top End
  133
- Cylinder Head Installation
  134
- Valve Sealing Test
  134
- Camshaft Installation / Timing
  135
- Camshaft Timing - Quick Reference
  139
- Valve Clearance Adjustment
  140
- Intake Valve Lash - Tappet Selection Matrix
  143
- Exhaust Valve Lash - Tappet Selection Matrix
  144
- Valve Cover Installation
  145
- Troubleshooting
  146
Chapter 4 Fuel System - General

150
- General Information
  152
- Special Tools
  152
- Efi Service Notes
  154
- Efi System Exploded View
  155
- Efi System Component Locations
  156
- Efi Operation Overview
  159
- Electronic Fuel Injection
  159
- Initial Priming / Starting Procedure
  159
- Principal Components
  159
- Fuel Tank
  160
- Fuel Tank Exploded View
  160
- Fuel Line Removal / Installation
  161
- Fuel Tank Removal
  162
- Fuel Tank Installation
  163
- Fuel Pump
  164
- Fuel Sender Test
  164
- Operation Overview
  164
- Fuel Pump Test
  165
- Fuel Pump Replacement
  166
- Ecu Replacement
  170
- Ecu Service
  170
- Electronic Control Unit (Ecu)
  170
- Operation Overview
  170
- Electronic Throttle Control (Etc)
  172
- Etc Replacement
  172
- Etc Test
  172
- Operation Overview
  172
- Cps Test
  173
- Crankshaft Position Sensor (Cps)
  173
- Operation Overview
  173
- Cps Replacement
  174
- Operation Overview
  175
- T-Map Sensor Replacement
  175
- T-Map Sensor Test
  175
- Temp / Manifold Absolute Pressure Sensor (T-Map)
  175
- Ect Sensor Replacement
  176
- Ect Sensor Test
  176
- Engine Coolant Temperature Sensor (Ect)
  176
- Operation Overview
  176
- Fuel System - General
  178
- Operation Overview
  178
- Pedal Position Sensor (Pps)
  178
- Pps Replacement
  178
- Pps Test
  178
- Fuel Injector Troubleshooting
  180
- Fuel Injectors
  180
- Operation Overview
  180
- Fuel Injector Replacement
  181
- Fuel Injector Test
  181
- Ignition Coil
  183
- Ignition Coil / Ht Lead Replacement
  183
- Ignition Coil Tests
  183
- Operation Overview
  183
- Efi Diagnostics
  185
- Instrument Cluster Trouble Code Display
  185
- Efi Troubleshooting
  190
- Diagnostic Software Version
  191
- Digital Wrench® Diagnostic Software Overview
  191
- Digital Wrench® Operation
  191
- Ecu Replacement
  191
- Guided Diagnostic Available
  191
- Special Tools
  191
- Digital Wrench® - Diagnostic Connector
  192
- Digital Wrench® Communication Errors
  192
- Digital Wrench® Serial Number Location
  192
- Digital Wrench® Updates
  193
- Digital Wrench® Version and Update
  193
- Digital Wrench® Feature Map
  195
- Engine Controller Reprogramming (Reflash)
  195
Chapter 5 Body / Steering / Suspension

200
- Torque Specifications
  202
- Special Tools
  203
- Multi-Function Pliers
  204
- Cab Frame / Headrests / Side Nets
  205
- Cab Frame Assembly
  205
- Doors (Le Only)
  207
- Chassis
  209
- Main Frame / Frame Supports / Front Bumper
  209
- Body Components
  211
- Dash Panels / Glove Box
  211
- Hood / Front Fenders / Front Fascia
  212
- Floor / Rear Fenders / Skid Plate / Storage
  213
- Seat Mounting / Seat Belts
  215
- Bucket Seats
  217
- Rear Cargo Box
  219
- Tailgate / Cargo Box Panels
  219
- Cargo Box Support
  220
- Box Installation
  221
- Box Removal
  221
- Body Component Removal
  222
- Front Bumper
  222
- Front Fascia
  222
- Hood
  222
- Lower Seat Base
  222
- Front Fenders
  223
- Dash Panels / Glove Box Removal
  224
- Rocker Panels
  224
- Rocker Panels - Crew
  226
- Front Floor
  227
- Main Floor
  227
- Rear Floor - Crew
  228
- Exploded View
  230
- Steering Assembly
  230
- Steering Wheel / Upper Steering Shaft Removal (Eps Models)
  231
- Steering Wheel Removal (Non-Eps Models)
  231
- Steering Shaft Bearing Replacement
  232
- Steering Shaft Removal (Non-Eps Models)
  232
- Power Steering Unit Installation
  233
- Power Steering Unit Removal
  233
- Exploded View
  235
- Front A-Arms
  235
- Front Lower A-Arm Installation
  236
- Front Lower A-Arm Removal
  236
- Front Upper A-Arm Installation
  237
- Front Upper A-Arm Removal
  237
- Ball Joint Removal
  238
- Ball Joint Service
  238
- Service Preparation
  238
- Ball Joint Installation
  239
- Exploded View
  241
- Rear A-Arms
  241
- Rear Upper A-Arm Installation
  242
- Rear Upper A-Arm Removal
  242
- Rear Lower A-Arm Removal
  243
- Rear Lower A-Arm Installation
  244
- Exploded View
  245
- Rear Stabilizer Bar / Linkage
  245
- Removal / Installation
  246
- Decal Replacement
  247
- Exploded View
  248
- Shock Removal / Installation
  248
- Shock Replacement
  248
- Shocks / Springs
  248
Chapter 6 Clutching

250
- Pvt System Fastener Torques
  252
- Special Tools and Supplies
  252
- Torque Specifications
  252
- Clutch Chart
  253
- High Altitude Clutch Charts
  253
- Drive Clutch Operation
  254
- Driven Clutch Operation
  254
- General Operation
  254
- Pvt System Overview
  254
- Maintenance / Inspection
  255
- Pvt Break-In (Drive Belt / Clutches)
  255
- Overheating / Diagnosis
  256
- Pvt Covers and Ducting Components
  257
- Pvt System Service
  257
- Pvt Disassembly
  258
- Pvt Assembly
  260
- Belt Removal
  262
- Drive Belt
  262
- Belt Inspection
  263
- Belt Installation
  263
- Pvt Break-In (Drive Belt / Clutches)
  263
- Drive Clutch Exploded View
  264
- Drive Clutch Service
  264
- Bearing Inspection
  265
- Clutch Disassembly
  265
- Drive Clutch Spring Inspection
  266
- Shift Weight Inspection
  266
- Button to Tower Clearance Inspection
  267
- Spider Removal
  267
- Clutch Inspection
  268
- Roller, Pin, and Thrust Washer Inspection
  268
- Moveable Sheave Bushing Inspection
  269
- Bushing Service
  270
- Clutch Assembly
  272
- Clutch Disassembly / Inspection
  274
- Driven Clutch Service
  274
- Exploded View
  274
- Clutch Assembly
  276
- 2014 Driven Clutch Service (Non-Ebs)
  278
- Clutch Disassembly / Inspection 2014 (Non-Ebs)
  278
- Exploded View 2014 (Non-Ebs)
  278
- Clutch Assembly 2014 (Non-Ebs)
  279
- 2014 Driven Clutch Service (Ebs)
  280
- Exploded View 2014 (Ebs)
  280
- Clutch Disassembly (Ebs)
  281
- Clutch Inspection
  282
- Clutch Assembly 2014 (Ebs)
  283
- Troubleshooting
  286
Chapter 7 Final Drive

288
- Special Tools
  289
- Torque Specifications
  289
- Bearing Carrier Inspection / Removal
  290
- Front Bearing Carrier
  290
- Bearing Replacement
  291
- Bearing Carrier Installation
  292
- Front Drive Shaft
  294
- Installation
  294
- Removal
  294
- Front Propshaft
  295
- Removal / Installation
  295
- Removal / Installation - Crew
  295
- Disassembly
  297
- Propshaft U-Joint Service
  297
- Assembly
  298
- Centralized Hilliard Exploded View
  299
- Front Gearcase - Centralized Hilliard
  299
- All Wheel Drive Operation
  300
- Awd Diagnosis
  301
- Front Gearcase Removal
  301
- Front Gearcase Disassembly / Inspection
  302
- Front Gearcase Assembly
  306
- Front Gearcase Installation
  308
- Inspection
  310
- Rear Bearing Carrier
  310
- Removal
  310
- Bearing Replacement
  311
- Installation
  313
- Rear Drive Shaft
  313
- Removal
  313
- Drive Shaft / CV Joint Handling Tips
  314
- Drive Shaft Service
  314
- Outer CV Joint / Boot Replacement
  314
- Inner Plunging Joint / Boot Replacement
  316
- Drive Shaft Cutaway View
  319
Chapter 8 Transmission

320
- Lubrication
  321
- Special Tools
  321
- Specifications
  321
- Torque Specifications
  321
- Transmission Mounting and Torque Values
  322
- Removal / Installation
  323
- Shift Lever
  323
- Adjustment
  324
- Inspection
  324
- Shift Cable
  324
- Transmission Removal
  325
- Transmission Installation
  329
- Differential Operation
  333
- Transmission Service
  333
- Transmission Disassembly
  334
- Planetary Differential Disassembly
  339
- Planetary Differential Bushing Replacement
  340
- Planetary Differential Assembly
  342
- Gear / Shaft / Bearing Inspection
  343
- Snorkel Gear Backlash Procedure
  344
- Troubleshooting
  350
- Troubleshooting Checklist
  350
- Exploded View
  351
- Transmission Exploded View
  351
Chapter 9 Brakes

354
- General Specifications
  356
- Brake System Service Notes
  358
- Brake Noise Troubleshooting
  359
- Hydraulic Brake System Operation
  360
- Brake System Assembly View
  361
- Installation
  362
- Master Cylinder
  362
- Removal
  362
- Foot Brake Pedal
  363
- Installation
  363
- Removal
  363
- Brake Bleeding / Fluid Change
  364
- Front Brake Pads
  366
- Pad Removal
  366
- Pad Assembly / Installation
  367
- Pad Inspection
  367
- Brake Burnishing Procedure
  368
- Caliper Exploded View
  369
- Caliper Removal
  369
- Front Caliper Service
  369
- Caliper Disassembly
  370
- Caliper Inspection
  371
- Caliper Assembly
  372
- Caliper Installation
  372
- Disc Inspection
  374
- Disc Runout
  374
- Front Brake Disc
  374
- Disc Removal / Replacement
  375
- Pad Inspection
  376
- Pad Removal
  376
- Rear Brake Pads
  376
- Brake Burnishing Procedure
  377
- Pad Installation
  377
- Caliper Exploded View
  378
- Rear Caliper Service
  378
- Caliper Exploded View Ranger Crew
  379
- Caliper Disassembly
  380
- Caliper Removal
  380
- Caliper Assembly
  381
- Caliper Inspection
  381
- Caliper Installation
  382
- Disc Inspection
  383
- Disc Runout
  383
- Rear Brake Disc
  383
- Disc Removal / Replacement
  384
- Brakes Lock
  385
- Caliper Overheats (Brakes Drag)
  385
- Pedal Vibration
  385
- Troubleshooting
  385
Chapter 10 Electrical

386
- Components Behind Dash Panel
  388
- Components under Hood
  388
- Components under Passenger Seat Base
  388
- Electrical Service Notes
  388
- General Information
  388
- Special Tools
  388
- Brake Light Switch
  389
- Headlamp Switch
  389
- Switches / Controls
  389
- Awd / 2Wd / Turf Switch
  390
- Ignition Key Switch
  390
- Transmission (Gear Position) Switch
  391
- Speed Sensor Location
  392
- Speed Sensor Testing
  392
- Vehicle Speed Sensor
  392
- Differential Solenoid Circuit Operation
  393
- Differential Solenoid Overview
  393
- Rear Diff Solenoid
  393
- Instrument Cluster
  395
- Overview
  395
- Rider Information Display
  396
- Information Display Area
  397
- Diagnostic Mode
  399
- Instrument Cluster Removal
  400
- Instrument Cluster Installation
  401
- All Wheel Drive Coils
  402
- Audio System (Le Only)
  402
- Diagnosing System Failures
  402
- Operation Overview
  402
- Headlight Adjustment
  403
- Headlight Bulb Replacement
  403
- Headlights
  403
- Headlight Housing Installation
  404
- Headlight Housing Removal
  404
- Led Lamp Replacement
  406
- Tail Light / Brake Light
  406
- Efi Component Information / Testing
  407
- Efi Diagnostics
  407
- Fuel Sender
  407
- Testing
  407
- Cooling System
  408
- Cooling System Break-Out Diagram
  408
- Coolant Temperature Sensor
  409
- Fan Control Circuit Bypass Test
  409
- Fan Control Circuit Operation / Testing
  409
- Fuse Box: Fuses / Relays / Circuit Breaker
  410
- Overview / Operation
  410
- Fuse Box Detail
  411
- Relay Operation
  412
- Charging System
  414
- Charging System "Break Even" Test
  414
- Charging System Stator (Alternator) Tests
  414
- Current Draw - Key off
  414
- Stator (Alternator) Replacement
  415
- Regulator / Rectifier
  416
- Charging System Testing Flow Chart
  417
- Battery Service
  418
- Battery Specifications
  418
- Battery Terminal Block
  418
- General Battery Information
  418
- Battery Conductance Analyzer
  419
- Battery off Season Storage
  419
- Battery Removal / Installation
  419
- Battery Testing
  419
- Load Test
  419
- Ocv - Open Circuit Voltage Test
  419
- Battery Charging Procedure
  420
- Starter Motor Removal
  421
- Starter System
  421
- Troubleshooting
  421
- Voltage Drop Test
  421
- Starter Motor Installation
  422
- Starter Solenoid Bench Test
  422
- Starter Solenoid Operation
  422
- Starting System Testing Flow Chart
  424
- Electronic Power Steering (Eps)
  425
- Eps Operation
  425
- Proper Eps System Diagnosing
  425
- Eps System Breakout
  426
- Eps Troubleshooting (Power Steering Non-Functional with Mil On)
  427
- Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
  428
- Eps Troubleshooting (Using Digital Wrench®)
  429

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