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RANGER 1000 2020
Polaris RANGER 1000 2020 Service Manual
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1
1.56
9850045
R01
-
2020-2021
RANGER
1000
Service
Manual
©
Copyright
Polaris
Inc.
DOOR
REMOV
AL
/
INST
ALLA
TION
1.
Open
the
door
and
lift
straight
off
the
hinge.
2.
Reinstall
by
gently
installing
the
door
over
both
hinges.
Ensure
proper
door
alignment.
BODY
/
FRAME
543
545
Table of Contents
Chapter 1 1 General Information
9
Table of Contents
9
Reference Information
11
Service Rules
11
Publication Part Numbers
12
Replacement Keys
13
Special Tools Website
14
Special Tools Index
15
Master Torque List
19
Vehicle Identification
26
Model Number Designation
26
Vehicle Identification Number (Vin) Designation
26
Vehicle and Engine Serial Number Location
26
Vehicle Specifications
27
Model Specifications - 3 Seat
27
Model Specifications - Crew
31
General Diagnostics Information Overview
35
Guided Symptom Diagnostic
35
Guided Symptom References
36
Engine and Drivability Diagnostic Procedures
37
Engine Cranks but Does Not Start
40
Crank no Start or Slow Crank
42
Over Heating
43
Warning Lights
44
Engine Troubleshooting
45
Cooling Troubleshooting
47
Digital Wrench
48
Digital Wrench® Software Overview
48
Special Tools
48
Guided Diagnostics
48
Digital Wrench® Software Installation and Updates
49
Digital Wrench® Communication Errors
50
Digital Wrench® - Diagnostic Connector
50
Digital Wrench® Serial Number Location
50
Digital Wrench® Feature Map
51
Engine Controller Reprogramming (Reflash)
52
Polaris Mobile Digital Wrench® (Pmdw)
53
Engine Electrical Diagnostics
54
Diagnostic Trouble Codes Overview
54
Master Trouble Code List
55
Cylinder Misfire Detection
66
Fluid Inspection
67
Fluid Leaks
67
Fuel System Diagnostics
68
Fuel System Troubleshooting
68
Pvt System Diagnostics
70
Pvt System Troubleshooting
70
Pvt System Overheating / Diagnosis
72
Transmission Diagnostics
73
Hard Shifting
73
Transmission Isolation
73
Final Drive Diagnostics
74
All Wheel Drive (Awd) Concerns
74
Driveshaft (Half Shaft) Diagnostics
74
Brake System Diagnostics
75
Brake Noise Troubleshooting
75
Brake Vibration
75
Caliper Overheats (Brakes Drag)
76
Poor Brake Performance
76
Brakes Lock
76
Steering / Suspension Diagnostics
77
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
78
Eps Troubleshooting (Using Digital Wrench®)
79
Shock Analysis
80
Electrical Diagnostics
81
Electrical Service Notes
81
Digital Multi-Meter (DMM) Notes
81
Static and Dynamic Testing
81
Connector Probing Guidelines
82
Testing Continuity / Resistance
83
Testing for a Short to Ground
83
Testing for a Short to Voltage
84
Testing for Intermittent Conditions
85
Testing Current Flow (Amperage)
85
Current Draw - Key off
86
Testing Voltage Drop
86
Maintenance Chapter 2 Maintenance 2
89
Chapter 2
91
General Information - Maintenance
91
Maintenance
91
Service Notes - Maintenance
91
Maintenance Specifications
92
Service Products
93
Periodic Maintenance
94
Periodic Maintenance Overview
94
Break-In Period
94
Pre-Ride Inspection
95
Maintenance Intervals
96
Maintenance Quick Reference
116
Grease Lubrication Points
118
Engine Maintenance
119
Engine Oil Level Inspection
119
Engine Oil and Filter Service
120
Valve Clearance Inspection
121
Cam Chain Tensioner Inspection
122
Cooling System Maintenance
124
Liquid Cooling System Overview
124
Coolant Strength / Type
124
Coolant Level Inspection
125
Cooling System Hose Inspection
126
Radiator Inspection
126
Coolant Replacement
126
Air Intake and Exhaust Maintenance
127
Air Filter Service
127
Engine Crankcase Breather Hose Inspection
128
Exhaust Spark Arrestor Inspection
129
Exhaust Heat Shield Inspection
130
Fuel System Maintenance
131
Fuel Line Inspection
131
Fuel Pump / Filter Inspection
131
Fuel Tank Vent Line Inspection
132
Pvt System Maintenance
133
Drive Belt Inspection
133
Pvt System Drying
133
Transmission and Front Gearcase Maintenance
134
Transmission Fluid Level Inspection
134
Transmission Fluid Replacement
134
Shift Cable Inspection
135
Shift Cable Adjustment
135
Front Gearcase Fluid Level Inspection
137
Front Gearcase Fluid Replacement
138
Final Drive Maintenance
140
Drive Shaft Boot Inspection
140
Wheel Service
140
Tire Inspection
141
Tire Pressure Inspection
141
Steering Maintenance
142
Steering System Inspection
142
Steering Wheel Free-Play Inspection
142
Tie Rod End Inspection
143
Wheel Toe Measurement
143
Wheel Toe Adjustment
144
Suspension Maintenance
145
Suspension Inspection
145
Spring Pre-Load Adjustment
145
Brake System Maintenance
146
Brake Fluid Level Inspection
146
Brake Fluid Replacement / Brake Bleeding
146
Brake Pad Inspection
148
Brake Disc Inspection
148
Brake Hose and Fitting Inspection
148
Electrical Maintenance
149
Battery Maintenance
149
Lead Acid Conventional Battery Maintenance
149
Dry Shipped Agm Battery Maintenance
149
Lead Acid Low Maintenance Battery Maintenance
149
Agm Low Maintenance Battery Maintenance
149
Battery Service
150
Chassis / Engine Electrical Ground
152
Throttle Pedal Inspection
152
Chapter 3 Engine / Cooling / Exhaust
153
Engine Service Specifications
155
Engine Specifications
155
Engine Torque Sequences
157
Valve Lash - Tappet Selection
159
Bearing Selection Identification Letters and Numbers
160
Connecting Rod Bearing Selection
161
Crankshaft Main Bearing Selection
161
Intake Service
162
Intake System Assembly View
162
Airbox Service
163
Intake Duct Service
164
Throttle Body Service
167
Intake Manifold Service
168
Intake Manifold Adapter Service
170
Exhaust Service
171
Exhaust System Assembly View
171
Muffler Service
172
Headpipe Service
174
Engine Service
176
Accessible Engine Components
176
Engine Mount Isolator Service
176
Crankshaft Pto Seal Replacement
178
Engine Removal & Installation
179
Engine Timing
184
Engine Service - Top End
187
Valve Cover Service
187
Valve Clearance Adjustment
188
Cam Chain Tensioner Service
189
Camshaft Sprocket Service
190
Camshaft Service
191
Camshaft Inspection
192
Cylinder Head Removal and Installation
193
Valve Service
196
Valve Inspection
198
Valve Seat Reconditioning
199
Cylinder Head Inspection
201
Combustion Chamber Cleaning
201
Engine Service - Bottom End
202
Oil Filter Adapter Service
202
Oil Sump Service
203
Oil Pump Service
204
Upper Crankcase Service
206
Balance Shaft Service
209
Crankshaft Service / Inspection
210
Cylinder / Piston Service
214
Crankcase Inspection
216
Cylinder Inspection
217
Piston Disassembly / Inspection
218
Connecting Rod Inspection
221
Stator Cover Service
222
Flywheel Service
224
Starter One-Way Clutch Service
225
Starter One-Way Clutch Inspection
227
Cooling System Service
228
Cooling System Specifications
228
Cooling System Assembly View
229
Coolant Service
232
Cooling System Pressure Test
233
Radiator Cap Pressure Test
234
Radiator Service
234
Radiator Fan Removal
236
Engine Oil Cooler Service
237
Thermostat Replacement
238
Water Pump Service
239
Heater Valve Service
244
Troubleshooting
245
Oil Pressure Test
245
Engine Cylinder Leakdown Test
245
Chapter 4 Engine Electrical
247
Engine Harness
249
Electronic Control Unit (Ecu)
254
Ecu Operation Overview
254
Ecu Service
254
Ecu Replacement
255
Crankshaft Position Sensor (Cps)
256
Cps Operation Overview
256
Cps Test
256
Cps Replacement
257
Electronic Throttle Control (Etc)
258
Etc Operation Overview
258
Etc Test
258
Etc Replacement
258
Etc Learn Procedure
258
Starter System Service
259
Starter Solenoid Operation
259
Starter Solenoid Bench Test
260
Starter Motor Service
260
Starting System Testing Flow Chart
262
Voltage Drop Test
263
Troubleshooting
263
Ignition System Service
264
Ignition Coil
264
Ignition Coil Operation Overview
264
Ignition Coil Service
264
Spark Plug
266
Spark Plug Inspection
266
Spark Plug Service
266
Ignition System Testing
268
Temp / Manifold Absolute Pressure Sensor (T-Map)
269
Tmap Operation Overview
269
T-Map Sensor Replacement
269
T-Map Sensor Test
269
Engine Coolant Temperature Sensor (Ect)
270
Ect Operation Overview
270
Ect Sensor Replacement
270
Ect Resistance Values
271
Ect Sensor Test
272
Engine Electrical
273
Oxygen Sensor Service
273
Oxygen Sensor Diagnostic Tips
274
Oxygen Sensor
273
Oxygen Sensor Information
273
Drive Mode Switch
276
Drive Mode Switch Description and Operation
276
Drive Mode Switch Replacement
276
Accelerator Position Sensor (Aps)
277
Aps Operation Overview
277
Aps Replacement
277
Aps Test
277
Cooling System Testing
278
Cooling System Break-Out Diagram
278
Fan Control Circuit Operation / Testing
279
Fan Control Circuit Bypass Test
279
Chapter 5 Fuel System
281
Fuel System Specifications
282
General Information - Fuel System
282
Service Notes - Fuel System
282
Electronic Fuel Injection
283
Fuel System Operation Overview
283
Initial Priming / Starting Procedure
283
Fuel System Components
283
Fuel System Component Locations
284
Fuel Lines
285
Fuel Line Routing
285
Fuel Line Quick Connect Removal
286
Fuel Supply Line Service
288
Vent Line Termination Fitting
289
Fuel Vent Line Routing
290
Fuel Vent Line Routing (Evap Models)
291
Fuel Tank
292
Fuel Tank Assembly View
292
Fuel Tank Service
293
Fuel Pump
296
Operation Overview
296
Fuel Sender Test
296
Fuel Pressure Test
297
Fuel Pump Replacement
299
Evap System
302
Carbon Canister Service
302
Purge Valve Service
303
Fuel Injector
304
Fuel Injector Operation Overview
304
Fuel Injector Troubleshooting
304
Fuel Injector Test
305
Fuel Injector Service
305
Chapter 6 Pvt System
309
Clutch Settings
310
General Information - Pvt System
310
Pvt Specifications
310
Pvt System Overview
311
Drive Clutch Operation
311
Driven Clutch Operation
311
Pvt Break-In (Drive Belt / Clutches)
311
Maintenance / Inspection
311
Drive Belt
312
Drive Belt Service
312
Driven Clutch Alignment
313
Pvt System Service
314
Pvt Covers and Ducting Assembly View
314
Pvt Clutch Cover Service
315
Drive Clutch Removal / Installation
317
Driven Clutch Removal / Installation
318
Inner Pvt Cover Service
319
Drive Clutch Service
322
Drive Clutch Assembly View
322
Drive Clutch Service
323
Drive Clutch Inspection
325
Roller Replacement
327
Bushing Service
328
Driven Clutch Service
330
Driven Clutch Assembly View
330
Driven Clutch Service
331
Helix and Movable Sheave Bushing Inspection
333
Bushing Service
334
Vehicle Creeping
335
Chapter 7 Transmission
337
General Information - Transmission
338
Service Notes - Transmission
338
Special Tools - Transmission
338
Transmission Specifications
338
Shift Cable
339
Shift Lever Removal / Installation
339
Shift Cable Inspection
339
Shift Cable Adjustment
340
Shift Cable Routing
343
Shift Cable Service
345
Transmission Service
350
Transmission Assembly View
350
Transmission Vent Line Routing
351
Transmission Removal and Installation
352
Transmission Disassembly
356
Differential Operation
359
Bevel Differential Disassembly
362
Bevel Differential Assembly
363
Gear, Shaft, Bearing Inspection
365
Snorkel Gear Backlash Procedure
366
Transmission Assembly
368
Chapter 8 Final Drive
375
Final Drive Specifications (2020)
377
Final Drive Specifications (2021+)
377
General Information - Final Drive
377
Service Notes - Final Drive
377
Rear Hub Identification
378
Front Bearing Carrier Service
379
Bearing Carrier Removal / Inspection
379
Bearing Replacement
381
Bearing Carrier Installation
382
Prop Shaft Service
385
Front Prop Shaft Service (Crew)
386
Rear Prop Shaft Service (Crew)
388
Propshaft U-Joint Service
390
Propshaft U-Joint Disassembly
390
Propshaft U-Joint Assembly
391
Front Gearcase Service 2020 Models
393
Front Gearcase Assembly View
393
Front Gearcase Removal
394
Front Gearcase Disassembly / Inspection
395
Front Gearcase Assembly
398
Front Gearcase Installation
400
Front Gearcase Service 2021+ Models
402
Front Gearcase Assembly View
402
Front Gearcase Removal
403
Front Gearcase Disassembly (Non-Adc)
405
Front Gearcase Inspection
408
Front Gearcase Assembly (Non-Adc)
410
Front Gearcase Installation
413
Front Gearcase Vent Line Routing
416
Front Drive Operation / Troublehsooting
417
All Wheel Drive (Awd) Operation
417
All Wheel Drive (Awd) Diagnosis
418
Rear Bearing Carrier Service
420
Rear Bearing Carrier Inspection
420
Rear Bearing Carrier Removal
420
Rear Bearing Carrier Bearing Replacement
421
Rear Bearing Carrier Installation
422
Rear Drive Shaft Service
424
Rear Drive Shaft Removal
424
Rear Drive Shaft Installation
425
Chapter 9 Steering / Suspension
433
General Information - Steering / Suspension
434
Service Notes - Steering / Suspension
434
Steering & Suspension Specifications
434
Steering & Suspension Assembly Views
435
Steering Assembly View
435
Front Suspension Assembly View
436
Rear Suspension Assembly View
438
Steering Assembly Service
439
Steering Wheel / Upper Steering Shaft Removal
439
Steering Rack Removal
440
Steering Rack Installation
440
Power Steering Unit Installation
442
Steering Inspection
443
Tie Rod End / Wheel Hub Inspection
444
Wheel Toe Measurement
444
Wheel Toe Adjustment
445
Front A-Arm Service
446
Front Lower A-Arm Removal / Installation
446
A-Arm Bushing Replacement
447
Ball Joint Service
449
Ball Joint Service Preparation
449
Ball Joint Removal
449
Ball Joint Installation
450
Rear A-Arm Service
452
Rear Upper A-Arm Removal
452
Rear Upper A-Arm Installation
453
A-Arm Bushing Replacement
454
Rear Lower A-Arm Removal
454
Rear Lower A-Arm Installation
455
Stabilizer Bar Service
455
Shock / Spring Service
456
Shock Analysis
456
Shock Removal and Installation
457
Shock Spring Replacement
458
Chapter 10 Brake System
459
General Information - Brake System
460
Service Notes - Brake System
460
Brake System Specifications
461
Brake System Service
462
Brake System Assembly View
462
Brake Line Routing
463
Brake Line Clocking
465
Brake Fluid Replacement / Brake Bleeding
468
Master Cylinder Service
470
Master Cylinder Removal
470
Master Cylinder Installation
471
Brake Pedal Replacement
471
Front Brake Pad Service
472
Front Brake Pad Removal
472
Front Brake Pad Inspection
472
Front Brake Pad Installation
473
Brake Burnishing Procedure
474
Front Caliper Service
475
Front Caliper Assembly View
475
Front Caliper Removal
476
Front Caliper Disassembly
477
Front Caliper Inspection
478
Front Caliper Assembly
478
Front Caliper Installation
479
Rear Brake Pad Service
480
Rear Brake Pad Removal
480
Rear Brake Pad Inspection
481
Rear Brake Pad Installation
481
Brake Burnishing Procedure
481
Rear Caliper Service
482
Rear Caliper Assembly View
482
Rear Caliper Removal
483
Rear Caliper Disassembly
484
Rear Caliper Inspection
484
Rear Caliper Assembly
485
Rear Caliper Installation
485
Brake Disc Service
486
Brake Disk Inspection
486
Disc Runout
487
Brake Disc Replacement
487
Chapter 11 Body / Frame
489
General Information - Body / Frame
491
Body Assembly Views
492
Chassis Assembly View
492
Chassis Assembly View (Crew)
493
Rops Assembly View
494
Rops Assembly View (Crew)
496
Dash Panel Assembly View
498
Front Body Assembly View
499
Floors and Bulkhead Assembly View
500
Roof Assembly View
502
Rear Panel Assembly View
503
Cargo Box Assembly View
504
Cab Frame Service
507
Windshield Service
507
Tip-Out Windshield Service
508
Tip-Out Windshield Adjustment
509
Roof Service
510
Headliner Service
513
Headliner Service (Crew)
513
Exterior Body Service
519
Front Bumper Service
519
Front Fender Service
520
Skid Plate Service
523
Front Fascia Service
524
Side Bezel Cover Service
526
Side Bezel Service
527
Rocker Panel Service
529
Rear Close-Off Panel Service
531
Decal Replacement
533
Cargo Box
536
Cargo Box Service
536
Door Service
538
Standard Door Panel Service
538
Door Latch Service
541
Window Regulator / Door Glass Service
541
Door Removal / Installation
544
Interior Body Service
545
Upper Dash Panel Service
545
Lower Dash Panel Service
547
Seat Back Service
550
Floor Panel Service
551
Lower Seat Base Removal
551
Roof Removal / Installation
552
Rear Panel Removal / Installation
553
Accessory Service
554
Chapter 12 Chassis / Body Electrical
555
General Information - Electrical System
557
Service Notes - Electrical
557
Body Electrical Specifications
558
Fuse Box / Circuit Protection
559
Fuse Box Breakout
559
Relay Operation
561
Vehicle Harness Service
563
Chassis Harness Routing
563
Chassis Harness Removal
570
Chassis Harness Installation
570
Switches / Controls Service
571
Transmission (Gear Position) Switch
572
Seat Belt Switch
572
Brake Pedal Switch Inspection
573
All Wheel Drive Circuit Service
573
Awd / 2Wd / Turf Switch
573
Operation Overview
573
Diagnosing System Failures
573
Vehicle Speed Sensor Service
574
Speed Sensor Location
574
Speed Sensor Testing
575
Rear Diff Solenoid Service
575
Differential Solenoid Overview
575
Differential Solenoid Circuit Operation
575
Differential Solenoid Replacement
576
Instrument Cluster Service
577
Instrument Cluster Pinouts
577
Charging System Service
578
Stator
578
Stator Inspection
578
Stator Service
578
Regulator / Rectifier Replacement
580
Charging System Testing Flow Chart
580
Charging System Troubleshooting Charging System "Break Even" Test
582
Charging System Stator (Alternator) Tests
582
Regulator Testing (900 Watt)
583
Battery Service
584
Battery Specifications
584
General Battery Information
584
Battery Terminal Block
584
Battery off Season Storage
585
Battery Identification
585
Lead Acid Conventional Battery
585
Lead Acid Conventional Battery Activation
585
Lead Acid Conventional Battery Inspection
586
Lead Acid Conventional Battery Charging and Testing
586
Lead Acid Conventional Battery Maintenance
587
Dry Shipped Agm Battery
587
Dry Shipped Agm Battery Activation
587
Dry Shipped Agm Battery Charging and Testing
589
Dry Shipped Agm Battery Maintenance
590
Lead Acid Low Maintenance Battery
591
Lead Acid Low Maintenance Battery Charging and Testing
591
Lead Acid Low Maintenance Battery Maintenance
591
Agm Low Maintenance Battery
592
Agm Low Maintenance Battery Charging
592
Agm Battery Charging - Low Charge
592
Agm Battery Charging - Deeply Discharged (below 3 Volts)
593
Agm Low Maintenance Battery Testing
593
Agm Low Maintenance Battery Maintenance
594
Battery Testing
594
Battery Conductance Analyzer
594
Battery Open Circuit Voltage Test (Ocv)
595
Battery Load Test
595
Battery Specific Gravity Test
596
Battery Charging Procedure
596
Electronic Power Steering (Eps)
597
Eps Operation
597
Lighting System Service
598
Headlamp Switch
598
Headlight Adjustment
599
Headlight Bulb Replacement
601
Headlight Housing Service
601
Tail Light Service
602
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Owner's Manual For Maintenance And Safety
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Polaris RANGER 1000 2020 Specifications
General
Brand
Polaris
Model
RANGER 1000 2020
Category
Offroad Vehicle
Language
English
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