Polaris RANGER 1000 2020 - Troubleshooting Common Issues; Drive Belt Issues

3
9850045 R01 - 2020-2021 RANGER 1000 Service Manual
© Copyright Polaris Inc.
3.1
ENGINE / COOLING / EXHAUST
CHAPTER 3
ENGINE / COOLING / EXHAUST
ENGINE SERVICE SPECIFICATIONS . ... ... . .. . .. . ... ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... .. .. . .. . .. . .. 3.3
ENGINE SPECIFICATIONS. .. .. . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . 3.3
ENGINE TORQUE SEQUENCES . . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . 3.5
VALVE LASH - TAPPET SELECTION . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . . 3.7
BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . . 3.8
CONNECTING ROD BEARING SELECTION . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . 3.9
CRANKSHAFT MAIN BEARING SELECTION . . .. . .. . .. . .. .. . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . . 3.9
INTAKE SERVICE . . .. . .. . .. . .. . .. . ... . .. . .. . ... ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . ... ... . .. . ..3.10
INTAKE SYSTEM ASSEMBLY VIEW .. ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ...3.10
AIRBOX SERVICE. . .. . .. . .. . .. . ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . .. 3.11
INTAKE DUCT SERVICE .. . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . .3.12
THROTTLE BODY SERVICE . . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . .3.15
INTAKE MANIFOLD SERVICE . .. .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . ..3.16
INTAKE MANIFOLD ADAPTER SERVICE. .. . .. . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. .3.18
EXHAUST SERVICE . . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .3.19
EXHAUST SYSTEM ASSEMBLY VIEW . .. . ... . .. . .. . .. . ... ... ... . .. . .. . .. . . .. . .. . .. . .. . .. . ... . .. . .. . .3.19
MUFFLER SERVICE . .. . ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... .. .. . .. . .3.20
HEADPIPE SERVICE. .. . .. . ... ... . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . ..3.22
ENGINE SERVICE . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . ... ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... .. .. . .. . .. . .3.24
ACCESSIBLE ENGINE COMPONENTS . . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . ..3.24
ENGINE MOUNT ISOLATOR SERVICE .. . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . ..3.24
CRANKSHAFT PTO SEAL REPLACEMENT . . .. . .. . ... ... . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . .3.26
ENGINE REMOVAL & INSTALLATION . . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ..3.27
ENGINE TIMING . ... ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .3.32
ENGINE SERVICE - TOP END . . .. . .. . .. . ... . .. . .. . .. . .. . ... .. .. . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. .3.35
VALVE COVER SERVICE.. . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . .3.35
VALVE CLEARANCE ADJUSTMENT. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. .3.36
CAM CHAIN TENSIONER SERVICE. .. . .. . .. . ... ... .. .. . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... .3.37
CAMSHAFT SPROCKET SERVICE. .. . .. . ... ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . ..3.38
CAMSHAFT SERVICE. .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . ..3.39
CAMSHAFT INSPECTION . . .. . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . ...3.40
CYLINDER HEAD REMOVAL AND INSTALLATION . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . ..3.41
VALVE SERVICE . . .. . .. . ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... .. .. . .. . .3.44
VALVE INSPECTION . .. .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ..3.46
VALVE SEAT RECONDITIONING . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . .3.47
CYLINDER HEAD INSPECTION . . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. .3.49
COMBUSTION CHAMBER CLEANING . .. . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ..3.49
ENGINE SERVICE - BOTTOM END. . .. . ... ... .. .. . .. . .. . ... ... ... . .. . .. . .. . . .. . .. . .. . .. . .. . ... . .. . .. . .3.50
OIL FILTER ADAPTER SERVICE . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .3.50
OIL SUMP SERVICE . . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . .3.51
OIL PUMP SERVICE . . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . .3.52