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Polaris RANGER XP 1000 2018-2019

Polaris RANGER XP 1000 2018-2019
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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 July 2018 (PN 9929399 R01)
© Copyright 2018 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. 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.
2018-2019 RANGER XP/ CREW 900/1000
Service Manual

Table of Contents

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Polaris RANGER XP 1000 2018-2019 Specifications

General IconGeneral
BrandPolaris
ModelRANGER XP 1000 2018-2019
CategoryOffroad Vehicle
LanguageEnglish

Summary

SAFETY WARNINGS

DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.

CAUTION

Indicates special precautions that must be taken to avoid vehicle damage or property damage.

IMPORTANT

Provides key reminders during disassembly, assembly and inspection of components.

CHAPTER 1: GENERAL INFORMATION

SERVICE RULES

Essential guidelines for efficient and safe service work.

MASTER TORQUE LIST

Specifications for tightening various fasteners to prevent damage.

VEHICLE SPECIFICATIONS

Key dimensions, capacities, and types for different models.

STANDARD BOLT TORQUE SPECIFICATION

Torque values for standard bolt sizes and grades.

METRIC BOLT TORQUE SPECIFICATION

Torque values for metric bolt sizes and grades.

CHAPTER 2: MAINTENANCE

PERIODIC MAINTENANCE CHART

Schedule for routine inspections, adjustments, and lubrication intervals.

PRE-RIDE INSPECTION

Daily checks to ensure the vehicle is safe and ready for operation.

ENGINE MAINTENANCE

Procedures for servicing the engine, including oil and filter changes.

COOLING SYSTEM MAINTENANCE

Steps for maintaining the liquid cooling system, including coolant levels.

FUEL SYSTEM AND AIR INTAKE MAINTENANCE

Procedures for servicing the fuel delivery and air intake systems.

PVT FINAL DRIVE WHEEL AND TIRE MAINTENANCE

Maintenance procedures for the PVT, final drive, wheels, and tires.

STEERING MAINTENANCE

Inspection and adjustment procedures for steering components.

SUSPENSION MAINTENANCE

Procedures for inspecting and adjusting suspension components.

BRAKE SYSTEM MAINTENANCE

Procedures for inspecting and servicing the brake system components.

ELECTRICAL AND IGNITION SYSTEM MAINTENANCE

Maintenance procedures for the battery, ignition, and charging systems.

CHAPTER 3: ENGINE COOLING HVAC SYSTEM

900 1000 ENGINE

General information, service notes, and special tools for the engine.

ENGINE DISASSEMBLY INSPECTION - TOP END (900 1000)

Procedures for disassembling and inspecting the engine's top end components.

ENGINE DISASSEMBLY INSPECTION - LOWER END (900 1000)

Procedures for disassembling and inspecting the engine's lower end components.

COOLING SYSTEM SERVICE (900 1000)

Service procedures for the engine's cooling system.

HVAC SYSTEM

Information and service procedures for the HVAC system.

CHAPTER 4: FUEL SYSTEM

FUEL SYSTEM OPERATION OVERVIEW

Explanation of how the electronic fuel injection system works.

FUEL SYSTEM COMPONENTS

Identification of key components in the fuel system.

FUEL PUMP SERVICE

Procedures for servicing the fuel pump assembly.

ELECTRONIC CONTROL UNIT (ECU)

Information on the ECU, its operation, and service.

ELECTRONIC THROTTLE CONTROL (ETC)

Information on the ETC, its operation, and replacement.

CRANKSHAFT POSITION SENSOR (CPS)

Information on the CPS, its operation, and testing.

TEMP MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)

Information on the T-MAP sensor, its operation, and replacement.

CHAPTER 5: PVT SYSTEM

TROUBLESHOOTING - PVT SYSTEM

Troubleshooting common PVT system issues and probable causes.

CHAPTER 6: TRANSMISSION

TROUBLESHOOTING - TRANSMISSION

Troubleshooting common transmission shifting difficulties.

CHAPTER 7: FINAL DRIVE

AWD DIAGNOSIS

Troubleshooting the AWD system when it will not engage.

CHAPTER 8: STEERING SUSPENSION

CHAPTER 9: BRAKE SYSTEM

BRAKE BLEEDING FLUID CHANGE

Procedures for bleeding the brake system and changing the fluid.

TROUBLESHOOTING - BRAKE SYSTEM

Troubleshooting common brake system issues like noise and poor performance.

CHAPTER 11: ELECTRICAL

ELECTRICAL DIAGNOSTICS

General guidelines and methods for diagnosing electrical problems.

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