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Polaris RANGER 1000 2021 User Manual

Polaris RANGER 1000 2021
610 pages
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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 November 2020 (PN 9850045 R01)
© Copyright 2020 Polaris 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.
2020-2021 RANGER 1000
Service Manual

Table of Contents

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Polaris RANGER 1000 2021 Specifications

General IconGeneral
BrandPolaris
ModelRANGER 1000 2021
CategoryOffroad Vehicle
LanguageEnglish

Summary

General Information

Safety Warnings

Details signal words and symbols used in the manual for safety clarification.

Master Torque List

Provides torque specifications for various components across multiple systems.

Engine Troubleshooting

Covers common engine issues like spark plug fouling and starting problems.

Cooling Troubleshooting

Addresses overheating issues, leaks, and temperature problems in the cooling system.

Electrical Diagnostics

Details static and dynamic testing methods for DC circuits using a DMM.

Maintenance

Engine / Cooling / Exhaust

Engine Service Specifications

Details standard and service limit specifications for top end engine components.

Engine Torque Sequences

Provides specific torque sequences for critical engine fasteners like crankcase and cylinder head.

Cylinder Head Removal and Installation

Step-by-step instructions for removing and installing the cylinder head assembly.

Engine Electrical

ECU Operation Overview

Explains the function of the Electronic Control Unit in managing EFI fuel and ignition.

Crankshaft Position Sensor (CPS)

Covers CPS operation, testing, and replacement procedures for engine timing.

Electronic Throttle Control (ETC)

Details ETC operation, testing, replacement, and the essential learn procedure.

Fuel System

Service Notes - Fuel System

Essential safety warnings and notes for working with the EFI fuel system.

Fuel Pressure Test

Provides steps to test fuel delivery problems by checking system pressure.

Fuel Pump Replacement

Step-by-step instructions for removing and installing the fuel pump assembly.

PVT System

Drive Belt Service

Details procedures for removing and installing the drive belt using specialized tools.

Driven Clutch Alignment

Explains how to use alignment washers for proper alignment of the driven clutch.

Drive Clutch Removal / Installation

Details procedures for removing and installing the drive clutch, including movable and stationary sheaves.

Transmission

Shift Cable Adjustment

Details the process for adjusting the shift cable to ensure correct gear engagement.

Transmission Disassembly

Step-by-step instructions for disassembling the transmission case, gears, and shafts.

Final Drive

Service Notes - Final Drive

Provides critical warnings and cautions for working on the final drive system.

Front Gearcase Removal

Step-by-step instructions for removing the front gearcase from the vehicle.

Front Gearcase Disassembly / Inspection

Covers draining fluid, removing cover, and inspecting internal gearcase components.

Front Gearcase Installation

Provides instructions for installing the front gearcase, including routing vent lines and connecting AWD harness.

Front Drive Operation / Troubleshooting

Explains AWD operation and provides diagnostic steps for when AWD will not engage.

Steering / Suspension

Service Notes - Steering / Suspension

Provides critical warnings and cautions for steering and suspension service procedures.

Steering Rack Removal

Step-by-step instructions for removing the steering rack from the vehicle.

Power Steering Unit Installation

Details the installation of the power steering unit, including torque specifications.

Ball Joint Service

Details ball joint service preparation, removal, and installation procedures.

Brake System

Service Notes - Brake System

Provides critical safety warnings and essential maintenance tips for the brake system.

Body / Frame

Chassis / Body Electrical

Service Notes - Electrical

Key notes for diagnosing electrical problems, including meter usage and component access.

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