Polaris RANGER XP 1000 2018

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1.8

9928487 R01 - 2018 RANGER XP 1000 Service Manual

TRANSMISSION

Snorkel Tool

PU-52547

Rear Driveshaft Seal Guide

2871699

Rear Output Seal Driver

2871698

Bearing Seal Driver (50 mm)

2871282

Crankcase Sealant

2871557 (3 bond)

3233901 (Loctite® 680)

FINAL DRIVE

Roll Pin Removal Tool

2872608

Axle Boot Clamp Tool

PU-48951

CV Boot Clamp Pliers

8700226

GENERAL INFORMATION

Main Page

Safety Warnings2
Trademarks3
Revision Index3
2018 Vehicle Updates3
Chapter Summary4
General Information/Contents5
Reference Information6
Service Rules6
Publication Part Numbers7
Replacement Keys7
Special Tools Website8
Special Tools Index9
Master Torque List15
Vehicle Identification Number (VIN) Designation22
Model Number Designation22
Engine Designation Number22
Vehicle and Engine Serial Number Location22
Vehicle Specifications23
2018 Ranger XP 1000 Specifications24
MISC. Specifications and Charts25
Conversion Table25
Standard/Metric Bolt Torque Specification26
Sae/Metric Tap/Drill Sizes27
Sae Tap / Drill Sizes27
Decimal Equivalents28
Maintenance/Contents29
Maintenance Service Notes31
Maintenance Special Tools31
Service Specifications - Maintenance32
Periodic Maintenance Overview33
Break-In Period33
Severe Use Definition33
Pre-Ride Inspection34
Maintenance Intervals35
25 Hour/250 Mile (400 Km) Service35
50 Hour/500 Mile (800 Km) Service36
75 Hour/750 Mile (1200 Km) Service37
100 Hour/1000 Mile (1600 Km) Service38
120 Hour/1250 Mile (2000 Km) Service39
150 Hour/1500 Mile (2400 Km) Service40
175 Hour/1750 Mile (2800 Km) Service41
200 Hour/2000 Mile (3200 Km) Service42
225 Hour/2250 Mile (3600 Km) Service43
250 Hour/2500 Mile (4000 Km) Service44
275 Hour/2750 Mile (4400 Km) Service45
300 Hour/3000 Mile (4800 Km) Service46
325 Hour/3250 Mile (5200 Km) Service47
350 Hour/3500 Mile (5600 Km) Service48
375 Hour/3750 Mile (6000 Km) Service49
400 Hour/4000 Mile (6400 Km) Service50
425 Hour/4250 Mile (6400 Km) Service51
450 Hour/4500 Mile (6800 Km) Service52
475 Hour/4750 Mile (7200 Km) Service53
500 Hour/5000 Mile (7600 Km) Service54
Maintenance Quick Reference55
Maintenance56
Grease Lubrication Points57
Maintenance Lubricants58
Polaris Lubricants, Maintenance and Service Products59
General Vehicle Inspection and Maintenance60
Pre-Ride/Daily Inspection60
Frame, Nuts, Bolts and Fasteners60
Engine Maintenance61
Engine Oil Level Inspection61
Engine Oil and Filter Replacement62
Engine Crankcase Breather Hose Inspection63
Engine Cylinder Leakdown Test63
Valve Clearance Inspection64
Cam Chain Tensioner Inspection66
Liquid Cooling System Overview67
Coolant Strength/Type67
Coolant Level Inspection67
Cooling System Hose Inspection68
Radiator Inspection69
Coolant Replacement69
Air Intake and Exhaust Maintenance70
Air Filter Replacement70
Exhaust Spark Arrestor Inspection71
Exhaust Heat Shield Inspection72
Fuel System Maintenance73
Fuel Line/Pump/Filter Inspection73
Fuel Tank Vent Line Inspection74
PVT System Maintenance75
Drive Belt Inspection75
PVT System Drying75
Transmission and Front Gearcase Maintenance76
Transmission Fluid Level Inspection76
Transmission Fluid Replacement76
Shift Cable Inspection/Adjustment77
Front Gearcase Fluid Level Inspection77
Front Gearcase Fluid Replacement78
Final Drive Maintenance79
Drive Shaft Boot Inspection79
Wheel Replacement79
Tire Inspection80
Tire Pressure Inspection80
Steering Maintenance81
Steering System Inspection81
Steering Wheel Free-Play81
Tie Rod End Inspection82
Wheel Toe Inspection82
Wheel Toe Adjustment83
Suspension Maintenance84
Suspension Inspection84
Shock Position Adjustment84
Brake System Maintenance85
Brake Fluid Level Inspection85
Brake Fluid Replacement/Brake Bleeding85
Brake Pad/Disc Inspection87
Brake Hose and Fitting Inspection87
Electrical Maintenance88
Battery Maintenance/Replacement88
Chassis/Engine Electrical Ground89
Spark Plug Replacement90
Throttle Pedal Inspection91
Engine/Cooling/Exhaust Contents93
Special Tools - Engine/Cooling System97
Engine Lubrication Specifications97
Oil Pressure Test98
Engine Oil Flow Chart99
Engine Break-In Period100
Engine Service Specifications101
Engine Torque Specifications103
Intake System Assembly View105
Intake Manifold Removal107
Intake Manifold Installation109
Exhaust System Assembly View111
Engine Service112
Accessible Engine Components112
Front Engine Mount Isolator Replacement112
Engine Removal113
Engine Removal (HVAC)114
Engine Installation116
Engine Installation (HVAC)119
Engine Disassembly/Inspection - Top End121
Valve Cover Removal121
Camshaft Removal121
Camshaft Sprocket Inspection122
Camshaft/Camshaft Bore Inspection123
Cylinder Head Removal124
Cylinder Head Warp Inspection125
Cylinder Head Disassembly126
Valve Inspection127
Combustion Chamber Cleaning128
Valve Sealing Test128
Valve Seat Reconditioning129
Intake/Exhaust Seat Cutter Diameter130
Engine Disassembly/Inspection - Lower End132
Stator Cover Removal/Inspection132
Water Pump Housing Removal133
Flywheel Removal134
Starter One-Way Clutch Inspection134
Starter One-Way Clutch Disassembly135
Crankcase Disassembly/Inspection136
Balance Shaft Removal/Inspection138
Crankshaft Removal/Inspection139
Crankcase Inspection141
Cylinder Inspection142
Cylinder/Piston Removal143
Piston Disassembly/Inspection144
Piston Ring Removal145
Piston Ring to Groove Clearance Inspection145
Piston Ring Installed Gap146
Piston-To-Cylinder Clearance146
Connecting Rod Inspection147
Bearing Selection Chart - Rod Bearings148
Engine Assembly - Lower End149
Bearing Selection Identification Letters and Numbers149
Connecting Rod Bearing Selection150
Crankshaft Main Bearing Selection150
Bearing Selection Chart - Rod/Main Bearings150
Upper Crankcase Preparation151
Piston Ring Installation151
Piston/Connecting Rod Assembly153
Cylinder/Piston Installation154
Crankshaft Installation156
Balance Shaft Installation157
Lower Crankcase Preparation158
Crankcase Assembly159
Starter One-Way Clutch Assembly163
Flywheel Installation164
Stator Cover Installation164
Engine Assembly - Top End165
Cylinder Head Assembly165
Cylinder Head Installation166
Camshaft Installation/Timing168
Timing View for Sprockets/Camshafts169
Camshaft Timing - Quick Reference172
Valve Clearance Adjustment173
Valve Lash - Tappet Selection175
Available Tappets175
Valve Cover Installation176
Cooling System Service177
Cooling System Assembly View177
Coolant Flow Diagram177
Cooling System Specifications178
Cooling System Pressure Test178
Recommended Coolant178
Radiator Cap Pressure Test179
Radiator Removal/Installation180
Radiator Fan Removal181
Thermostat Replacement182
Cooling System Bleeding Procedure183
Water Pump Removal185
Water Pump Installation186
Water Pump Service187
Water Pump Assembly View189
Troubleshooting - Engine190
Cooling System Troubleshooting191
HVAC System Fastener Torques192
Special Tools - HVAC192
HVAC System Timing192
HVAC System Overview193
Air Conditioning Description193
HVAC Assembly View194
HVAC and Heater Lines194
HVAC Ducting195
A/C System Diagram196
Safety Equipment197
HVAC System Components197
HVAC Maintenance200
Compressor Drive Belt Inspection200
A/C Condenser Cleaning201
HVAC Filter Inspection/Replacement202
Refrigerant202
Reclamation and Charging with Recovery/Charging Unit203
HVAC System Service204
Compressor Drive Belt Replacement204
Service Video204
Compressor Replacement206
Compressor Oil Specifications206
Compressor Oil Inspection207
Alternator Inspection/Replacement208
HVAC Cover Mount Replacement209
Condenser Replacement/Removal210
Condenser Installation211
High Pressure Cut-Out (HPCO) Switch Overview213
HPCO Switch Replacement213
Expansion Valve/Evaporator Coil Replacement213
Heater/Evaporator Unit Replacement/Removal214
Heater/Evaporator Unit Installation215
Heater Coil Replacement216
Blower Unit Replacement216
A/C Thermostat Overview217
Heater Valve Replacement217
HVAC Control Service218
HVAC Control Operation Overview218
A/C/Fan Switch Testing218
Temperature Potentiometer Testing218
HVAC Breakout Diagram219
Teoubleshooting - HVAC220
Blower Motor Does Not Operate220
Blower Motor Operates Normally but Air Flow Is Insufficient220
Insufficient Cooling (Air Flow and Compressor Operation Are Normal)220
Gauge Pressure Related Troubleshooting221
Temperature/Pressure Chart222
Evaporator222
Condenser222
Poor A/C Performance223
Engine Coolant Bypassing the Heater Valve223
Fuel System/Contents225
Service Notes - Fuel System227
Special Tools - Fuel System228
Fuel Pressure Gauge Kit - PU-43506-A228
Fuel Pressure Gauge Adapter - PS-48762228
Digital Wrench Diagnostic Kit - PU-47063-B228
Service Specifications - Fuel System229
Digital Wrench Smartlink Module Kit - PU-47471229
Digital Wrench - Diagnostic Connector229
Digital Wrench - Download Website229
Electronic Fuel Injection230
Fuel System Operation Overview230
Initial Priming/Starting Procedure230
Fuel System Components230
Fuel System Component Locations231
Fuel Line Routing233
Fuel Line Removal/Installation234
Fuel Vent Line Routing235
Fuel Vent Line Routing (EVAP Models)236
Vent Line Termination Fitting237
Fuel Line Quick Connect Removal238
Fuel Tank Service240
Fuel Tank Assembly View240
Fuel Flow240
Fuel Tank Removal241
Fuel Tank Installation242
Fuel Pump Service245
Operation Overview245
Fuel Sender Test245
Fuel Pump Test246
Fuel Pump Replacement247
Electronic Control Unit (ECU)250
ECU Operation Overview250
ECU Service250
ECU Replacement251
ETC Learn Procedure251
Electronic Throttle Control (ETC)252
ETC Operation Overview252
ETC Test/Replacement252
Throttle Control Switch253
Drive Mode Switch Description and Operation253
Throttle Control Switch Replacement254
Crankshaft Position Sensor (CPS)255
CPS Operation Overview255
CPS Test/Connector255
CPS Replacement256
ECT Sensor Replacement259
Pedal Position Sensor (PPS)260
PPS Operation Overview260
PPS Test/Replacement260
Fuel Injector Service261
Fuel Injector Operation Overview261
Fuel Injector Troubleshooting261
Fuel System Diagnosis265
Instrument Cluster Trouble Code Display265
Diagnostic Trouble Code Table266
Cylinder Misfire Detection270
Fuel System Troubleshooting271
Digital Wrench Operation272
Digital Wrench Diagnostic Software Overview272
Special Tools272
Diagnostic Software Version272
Digital Wrench Communication/Diagnostic273
Digital Wrench Serial Number Location274
Digital Wrench Version and Update ID274
Digital Wrench Updates274
Digital Wrench Feature Map276
Engine Controller Programming (Reflash)277
Polaris Mobile Digital Wrench (PMDW)280
PVT System/Contents281
Service Notes - PVT System283
Special Tools - PVT System283
Service Specifications - PVT System284
Clutch Chart284
PVT System Overview285
Drive/Driven Clutch Operation285
PVT Break-In (Drive Belt/Clutches)285
Maintenance/Inspection285
Drive Belt Service286
Belt Removal286
Belt Inspection287
Belt Installation288
Driven Clutch Alignment289
PVT System Service290
PVT Covers and Ducting Assembly View290
PVT Duct Removal/Install291
Outlet/Inlet Duct Removal/Installation291
PVT Inner Cover Disassembly292
PVT Inner Cover Assembly293
Drive Clutch Service298
Drive Clutch Assembly View298
Clutch Disassembly300
Bearing Inspection300
Button to Tower Clearance Inspection301
Spider Removal301
Roller, Pin and Thrust Washer Inspection301
Shift Weight Inspection302
Clutch Inspection302
Drive Clutch Spring Inspection304
Drive Clutch Bushing Inspections305
Bushing Service305
Moveable Sheave - Bushing Removal305
Drive Clutch Bushing Installation306
Cover Bushing Removal/Installation306
Clutch Assembly307
One-Way Bearing Bushing Replacement307
Driven Clutch Service310
Driven Clutch Assembly View310
Driven Clutch Disassembly (EBS)311
Helix and Movable Sheave Bushing Inspection312
Movable Sheave Bushing Removal/Installation312
Helix Bushing Removal/Installation313
Driven Clutch Assembly314
Troubleshooting315
Overheating/Diagnosis318
Clutch Drive Belt and Cover Related Issues: Diagnosis318
Operating in Low Gear318
Transmission/Contents321
Service Notes - Transmission322
Special Tools - Transmission322
Service Specifications - Transmission322
Transmission Assembly View323
Transmission Vent Line Routing324
Shift Cable Service/Inspection325
Shift Lever Removal/Installation325
Shift Cable Adjustment326
Transmission Service327
Differential Operation327
Transmission Removal329
Transmission Installation332
Transmission Disassmebly335
Gear Cluster Disassembly337
Snorkel Tube Removal/Disassembly337
Planetary Differential Disassembly339
Planetary Differential Bushing Replacement340
Ring Gear Bushing Replacement340
Planet Gear Bushing Replacement340
Differential Cover Bushing Replacement341
Female Side Gear Bushing Replacement341
Planetary Differential Assembly342
Gear, Shaft, Bearing Inspection343
Snorkel Gear Backlash Procedure344
Transmission Assembly346
Troubleshooting - Transmission351
Final Drive/Contents353
Service Notes - Final Drive355
Special Tools - Final Drive355
Service Specifications - Final Drive355
Front Gearcase Vent Line Routing356
Front Bearing Carrier Service357
Bearing Carrier Removal/Inspection357
Bearing Replacement/Removal/Installation358
Bearing Carrier Installation359
Front Drive Shaft Service/Removal/Installation361
Prop Shaft Service362
Front Prop Shaft Removal362
Front Prop Shaft Installation365
Rear Prop Shaft Removal/Installation368
Propshaft U-Joint Service/Disassembly369
Propshaft U-Joint Assembly370
Front Gearcase Service372
Front Gearcase Assembly View372
All Wheel Drive (AWD) Operation373
All Wheel Drive (AWD) Diagnosis374
AWD will Not Engage374
Front Gearcase Removal/Disassembly/Inspection375
Front Gearcase Assembly378
Front Gearcase Installation381
Front Gearcase (ADC) Operation382
Front Gearcase (ADC) Disassembly/Inspection383
Front Gearcase (ADC) Reassembly386
Front Gearcase (ADC) Troubleshooting389
Rear Bearing Carrier Service/Inspection/Removal392
Rear Bearing Carrier Bearing Replacement393
Rear Bearing Carrier Installation394
Rear Drive Shaft Service/Removal395
Rear Drive Shaft Installation396
Drive Shaft Service397
Drive Shaft Cutaway View397
Drive Shaft/CV Joint Handling Tips397
Outer CV Joint/Boot Replacement398
Inner Plunging Joint/Boot Replacement400
Steering and Suspension/Contents403
Service Notes - Steering/Suspension404
Special Tools - Steering/Suspension404
Service Specifications - Steering/Suspension404
Steering Assembly Service/View405
Steering Wheel/Upper Steering Shaft Removal406
Steering Rack Removal407
Steering Rack Installation408
Steering Shaft Bearing Replacement409
Power Steering Unit Installation410
Steering Inspection411
Tie Rod End/Wheel Hub Inspection412
Front A-Arm Service414
Front Lower A-Arm Removal/Installation414
A-Arm Bushing Replacement415
Front Upper A-Arm Removal/Installation415
Ball Joint Service Preparation417
Ball Joint Removal418
Ball Joint Installation419
Rear A-Arm Service420
Rear Upper A-Arm Removal420
Rear Upper A-Arm Installation421
Rear Lower A-Arm Removal422
Stabilizer Bar Service423
Rear Lower A-Arm Installation423
Rear Stabilizer Bar Removal/Installation423
Shock/Spring Service424
Shock Removal/Installation424
Shock Spring Replacement424
Brake System/Contents425
Service Notes - Brake System427
Special Tools - Brake System427
Service Specifications - Brake System428
Brake System Assembly View429
Brake Line Routing430
Front Brake Lines from Calipers to Master Cylinder430
Rear Brake Line from Master Cylinder to Junction Block431
Rear Brake Lines from Junction Block to Rear Calipers431
Brake Line Clocking432
Master Cylinder Service/Removal435
Master Cylinder Installation436
Brake Pedal Replacement437
Front Brake Pad Service/Removal438
Front Brake Pad Inspection/Installation439
Brake Burnishing Procedure440
Front Caliper Assembly View441
Front Caliper Removal442
Front Caliper Disassembly443
Front Caliper Inspection/Assembly444
Front Caliper Installation445
Front Brake Disc Service446
Disc Runout446
Brake Disc Inspection446
Rear Brake Pad Service/Removal448
Rear Brake Pad Inspection/Installation449
Rear Caliper Assembly View451
Rear Caliper Removal452
Rear Caliper Disassembly453
Rear Caliper Assembly/Inspection454
Rear Caliper Installation455
Rear Brake Disc Service456
Brake Disk Inspection456
Brake Disc Replacement457
Brake Noise Troubleshooting458
Brakes Squeal/Poor Brake Performance458
Pedal Vibration458
Caliper Overheats (Brakes Drag)458
Body and Frame/Contents459
Service Notes - Body/Frame461
Special Tools - Body/Frame461
Decal Replacement461
Body Components Assembly Views462
Chassis Assembly View462
Dash Panel/Glove Box Assembly View463
Front Body Assembly View465
Floors/Fender Assembly View466
Seat Components Assembly View468
Cab Frame Assembly View470
Door Assembly View471
Roof Assembly View472
Rear Panel Assembly View476
Cargo Box Assembly View477
Tailgate Assembly477
Cargo Box Assembly478
Cargo Box Frame Assembly479
Cab Frame Service480
Door and Roof Removal/Installation480
Rear Panel Removal/Installation481
Rear Cargo Box Service482
Cargo Box Removal/Installation482
Body Component Service483
Driver's Seat Removal483
Front Bumper Removal483
Front Fender Service484
Upper Fender Removal/Installation484
Lower Fender Service485
Lower Fender Installation486
Front Fascia Service/Removal487
Front Fascia Installation488
Dash Panels/Glove Box Removal489
Upper Dash Removal489
Lower Dash Panel Removal491
Rocker Panel Removal492
Floor Removal493
Floor Installation494
Accessory Service495
Electrical/Contents497
Service Notes - Electrical500
Special Tools - Electrical501
Service Specifications - Electrical501
Switches/Control Service502
Brake/Headlamp Switch502
Ignition Key Switch503
Awd/2Wd/Turf Switch503
Transmission (Gear Position) Switch504
Seat Belt Switch504
Deive Mode Switch505
Digital Wrench Values505
Vehicle Speed Sensor Service506
Speed Sensor Location/Testing506
Rear Diff Solenoid Service507
Differential Solenoid Overview507
Differential Solenoid Circuit Operation507
Differential Solenoid Replacement508
Instrument Cluster Overview509
Speedometer510
Tachometer510
Mode and Toggle Buttons510
Indicator Lamps510
Rider Information Center511
Mode Information Displays511
Accessing Menus and Options512
Gauge Settings Menu512
Backlight Color/Brightness512
Clock512
Display Units (Standard/Metric)513
Trip Meter/Time513
Programmable Service Interval513
Engine Error Codes514
Instrument Cluster Pinouts514
Instrument Cluster Service515
All Wheel Drive Coil Service516
Diagnosis System Failures516
Headlight Service/Adjustment517
Headlight Bulb Replacement519
Headlight Housing Removal519
Headlight Housing Installation520
Tail Light Service520
Cooling System Break-Out Diagram521
Fan Control Circuit Operation/Testing522
Fan Control Circuit Bypass Test522
Coolant Temperature Sensor522
Ignition Coil Service523
Ignition Coil Operation Overview523
Ignition Coil/ HT Lead Replacement523
Primary/Secondary Ignition Coil Tests524
Ignition Coil Resistance Readings524
Fuses/Relays/Circuit Break Service525
Fuse Box Operation Overview525
Relay Operation527
Rear Diff Solenoid Relay528
Charging System Service529
Current Draw - Key off529
Charging System "Break Even" Test529
Charging System Stator (Alternator) Tests530
Stator Replacement530
Alternator Replacement531
Regulator/Rectifier Replacement533
Charging System Testing Flow Chart534
Electrical Diagnostics535
Electrical Service Notes535
Digital Multi-Meter (DMM) Notes535
Static and Dynamic Testing535
Connector Probing Guidelines536
Front/Back Probing536
Break out536
Testing Continuity/Resistance537
Testing for a Short to Ground538
Testing for a Short to Voltage539
Testing for Intermittent Conditions539
Testing Current Flow (Amperage)540
Testing Parasitic Draw540
Testing Voltage Drop541
Battery Specifications542
General Battery Information542
Battery Service542
Battery Terminal Block543
Battery off Season Storage543
Battery Testing543
Open Circuit Voltage and Load Test543
Battery Conductance Analyzer544
Battery Charging Procedure544
Starter System Service545
Voltage Drop Test545
Starter Motor Removal545
Starter Motor Installation546
Starter Solenoid Bench Test546
Starter Solenoid Operation547
Starting System Testing Flow Chart548
Electronic Power Steering (EPS)549
EPS Operation549
Proper EPS System Diagnosing549
EPS Torque Offset Procedure549
EPS System Breakout550
EPS Troubleshooting (Power Steering Non-Functional with Mil On)551
EPS Troubleshooting (Power Steering Non-Functional with Mil Off)552
EPS Troubleshooting (Using Digital Wrench)553
Index555
Chassis Schematic - BASE 2018-Ranger XP 1000563
Chassis Schematic - HVAC 2018-Ranger XP 1000564
Cargo Box Schematic - 2018-Ranger XP 1000565

Polaris RANGER XP 1000 2018 - Page 12

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