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RANGER CREW 900 2014
Polaris RANGER CREW 900 2014 User Manual
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10
9924880
Rev
2-
1/10/2014
-
2013
/
2014
RANGER
XP
900
-
2014
RANGER
XP
900
/
CREW
900
Service
Manual
©
Copyright
Polaris
Sales
Inc.
10.41
EPS
SYSTEM
BREAKOUT
ELECTRICAL
425
427
Table of Contents
Chapter 1 1 General Information
4
Table of Contents
4
Vehicle Identification
5
Model Number Designation
5
Engine Designation Number
5
Vehicle Identification Number (Vin) Designation
5
Vehicle and Engine Serial Number Locations
6
Vehicle Information
7
Publication Numbers
7
Replacement Keys
7
Special Tools
8
General Specifications
9
General Specifications: 2013 - 2014 Ranger Xp 900 / Eps
9
Detailed Specifications: 2013 - 2014 Ranger Xp 900 / Eps
10
General Specifications: 2014 Ranger Crew 900 / Eps
11
Detailed Specifications: 2014 Ranger Crew 900 / Eps
12
Clutch Chart
13
Misc. Specifications and Charts
14
Conversion Table
14
Standard Bolt Torque Specification
15
Metric Bolt Torque Specification
15
Sae Tap / Drill Sizes
16
Metric Tap / Drill Sizes
16
Decimal Equivalents
17
Maintenance Chapter 2 Maintenance 2
18
Break-In Period
20
Maintenance
20
Maintenance Chart Key
20
Periodic Maintenance Chart
20
Periodic Maintenance Overview
20
Pre-Ride - 50 Hour Maintenance Interval
21
50 - 500 Hour Maintenance Interval
22
Maintenance Quick Reference
23
Grease Lubrication Points
25
Polaris Lubricants, Maintenance and Service Products
28
Service Products and Lubricants
28
Frame, Nuts, Bolts, and Fasteners
29
General Vehicle Inspection and Maintenance
29
Pre-Ride / Daily Inspection
29
Shift Cable Inspection / Adjustment
29
Fuel Lines
31
Fuel Pump / Fuel Filters
31
Fuel System and Air Intake
31
Fuel System Warning
31
Engine Intake Pre-Filter Screen Service
32
Vent Line
32
Air Filter Service
33
Engine Air Intake Exploded View
34
Engine
35
Engine Oil and Filter Change
35
Engine Oil Level
35
Engine Crankcase Breather Hose Inspection
37
Engine Cylinder Leakdown Test
37
Valve Clearance Inspection
37
Exhaust - Spark Arrestor
39
Specification Chart
41
Transmission and Front Gearcase
41
Transmission Lubrication
41
Front Gearcase Lubrication
42
Coolant Level Inspection
44
Coolant Strength / Type
44
Cooling System
44
Liquid Cooling System Overview
44
Cooling System Hoses
45
Coolant Drain / Fill
46
Radiator Inspection / Cleaning
46
Drive Clutch / Driven Clutch / Belt Service
47
Pvt / Final Drive / Wheel and Tire
47
Pvt Drying
47
Pvt Intake Pre-Filter Service
47
Drive Shaft Boot Inspection
48
Wheel and Hub Torque Table
48
Wheel Installation
48
Wheel Removal
48
Tire Inspection
49
Tire Pressure
49
Battery Charging / off Season Storage
50
Battery Installation
50
Battery Maintenance
50
Battery Removal
50
Electrical and Ignition System
50
Chassis / Engine Electrical Ground
51
Spark Plug Service
51
Steering
53
Steering Inspection
53
Tie Rod End / Wheel Hub Inspection
53
Wheel Toe Adjustment
54
Wheel Toe Alignment Inspection
54
Shock Position Adjustment
56
Spring Pre-Load Adjustment
56
Suspension
56
Suspension Inspection
56
Brake Fluid Inspection
57
Brake Hose and Fitting Inspection
57
Brake Pad / Disc Inspection
57
Brake System
57
Chapter 3 Engine
58
General Information
61
Special Tools
61
Engine Lubrication Specifications
62
Oil Pressure Test
62
Engine Oil Flow Chart
64
Engine Service Specifications
65
Engine Specifications
65
Engine Detail - Torque Values / Sequences / Assembly Notes
67
Main Engine Components - Torque Specification and Sequence
67
Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
68
Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
69
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
70
Spark Plugs / Starter / Thermostat Housing / Trans Joint / Valve Cover
71
Engine Exhaust System
72
Exhaust Removal / Installation
72
Cooling System Pressure Test
73
Engine Cooling System
73
Radiator Cap Pressure Test
73
Radiator Fan Removal
74
Radiator Removal / Coolant Drain
74
Thermostat Replacement
75
Cooling System Exploded View
77
Cooling System Bleeding Procedure
78
Water Pump Removal
78
Water Pump Installation
79
Water Pump Service
80
Accessible Engine Components
84
Engine Removal
84
Engine Service
84
Engine Installation
87
Engine Mounting and Torque Values
91
Engine Break-In Period
92
Engine Lubrication Specifications
92
Camshaft Removal
93
Engine Disassembly / Inspection - Top End
93
Valve Cover Removal
93
Camshaft / Camshaft Bore Inspection
95
Camshaft Sprocket Inspection
95
Cylinder Head Inspection
97
Cylinder Head Removal
97
Cylinder Head Warp Inspection
97
Cylinder Head Disassembly
98
Valve Inspection
98
Combustion Chamber Cleaning
100
Valve Seat Reconditioning
100
Engine Disassembly / Inspection - Lower End
103
Stator Cover Removal / Inspection
103
Flywheel Removal
104
Water Pump Housing Removal
104
Starter One-Way Clutch Disassembly
105
Starter One-Way Clutch Assembly
106
Crankcase Disassembly
107
Balance Shaft Removal / Inspection
109
Crankshaft Removal / Inspection
110
Crankcase Inspection
113
Cylinder / Piston Removal
113
Cylinder Inspection
114
Piston Disassembly / Inspection
115
Piston Ring Removal
116
Piston Ring Installed Gap
117
Piston Ring to Groove Clearance Inspection
117
Connecting Rod Inspection
118
Piston-To-Cylinder Clearance
118
Bearing Selection Identification Letters and Numbers
120
Engine Assembly - Lower End
120
Connecting Rod Bearing Selection
121
Crankshaft Main Bearing Selection
121
Piston Ring Installation
122
Upper Crankcase Preparation
122
Piston / Connecting Rod Assembly
123
Cylinder / Piston Installation
124
Crankshaft Installation
125
Balance Shaft Installation
126
Crankcase Assembly
127
Lower Crankcase Preparation
127
Flywheel Installation
131
Stator Cover Installation
132
Cylinder Head Assembly
133
Engine Assembly - Top End
133
Cylinder Head Installation
134
Valve Sealing Test
134
Camshaft Installation / Timing
135
Camshaft Timing - Quick Reference
139
Valve Clearance Adjustment
140
Intake Valve Lash - Tappet Selection Matrix
143
Exhaust Valve Lash - Tappet Selection Matrix
144
Valve Cover Installation
145
Troubleshooting
146
Chapter 4 Fuel System - General
150
General Information
152
Special Tools
152
Efi Service Notes
154
Efi System Exploded View
155
Efi System Component Locations
156
Efi Operation Overview
159
Electronic Fuel Injection
159
Initial Priming / Starting Procedure
159
Principal Components
159
Fuel Tank
160
Fuel Tank Exploded View
160
Fuel Line Removal / Installation
161
Fuel Tank Removal
162
Fuel Tank Installation
163
Fuel Pump
164
Fuel Sender Test
164
Operation Overview
164
Fuel Pump Test
165
Fuel Pump Replacement
166
Ecu Replacement
170
Ecu Service
170
Electronic Control Unit (Ecu)
170
Operation Overview
170
Electronic Throttle Control (Etc)
172
Etc Replacement
172
Etc Test
172
Operation Overview
172
Cps Test
173
Crankshaft Position Sensor (Cps)
173
Operation Overview
173
Cps Replacement
174
Operation Overview
175
T-Map Sensor Replacement
175
T-Map Sensor Test
175
Temp / Manifold Absolute Pressure Sensor (T-Map)
175
Ect Sensor Replacement
176
Ect Sensor Test
176
Engine Coolant Temperature Sensor (Ect)
176
Operation Overview
176
Fuel System - General
178
Operation Overview
178
Pedal Position Sensor (Pps)
178
Pps Replacement
178
Pps Test
178
Fuel Injector Troubleshooting
180
Fuel Injectors
180
Operation Overview
180
Fuel Injector Replacement
181
Fuel Injector Test
181
Ignition Coil
183
Ignition Coil / Ht Lead Replacement
183
Ignition Coil Tests
183
Operation Overview
183
Efi Diagnostics
185
Instrument Cluster Trouble Code Display
185
Efi Troubleshooting
190
Diagnostic Software Version
191
Digital Wrench® Diagnostic Software Overview
191
Digital Wrench® Operation
191
Ecu Replacement
191
Guided Diagnostic Available
191
Special Tools
191
Digital Wrench® - Diagnostic Connector
192
Digital Wrench® Communication Errors
192
Digital Wrench® Serial Number Location
192
Digital Wrench® Updates
193
Digital Wrench® Version and Update
193
Digital Wrench® Feature Map
195
Engine Controller Reprogramming (Reflash)
195
Chapter 5 Body / Steering / Suspension
200
Torque Specifications
202
Special Tools
203
Multi-Function Pliers
204
Cab Frame / Headrests / Side Nets
205
Cab Frame Assembly
205
Doors (Le Only)
207
Chassis
209
Main Frame / Frame Supports / Front Bumper
209
Body Components
211
Dash Panels / Glove Box
211
Hood / Front Fenders / Front Fascia
212
Floor / Rear Fenders / Skid Plate / Storage
213
Seat Mounting / Seat Belts
215
Bucket Seats
217
Rear Cargo Box
219
Tailgate / Cargo Box Panels
219
Cargo Box Support
220
Box Installation
221
Box Removal
221
Body Component Removal
222
Front Bumper
222
Front Fascia
222
Hood
222
Lower Seat Base
222
Front Fenders
223
Dash Panels / Glove Box Removal
224
Rocker Panels
224
Rocker Panels - Crew
226
Front Floor
227
Main Floor
227
Rear Floor - Crew
228
Exploded View
230
Steering Assembly
230
Steering Wheel / Upper Steering Shaft Removal (Eps Models)
231
Steering Wheel Removal (Non-Eps Models)
231
Steering Shaft Bearing Replacement
232
Steering Shaft Removal (Non-Eps Models)
232
Power Steering Unit Installation
233
Power Steering Unit Removal
233
Exploded View
235
Front A-Arms
235
Front Lower A-Arm Installation
236
Front Lower A-Arm Removal
236
Front Upper A-Arm Installation
237
Front Upper A-Arm Removal
237
Ball Joint Removal
238
Ball Joint Service
238
Service Preparation
238
Ball Joint Installation
239
Exploded View
241
Rear A-Arms
241
Rear Upper A-Arm Installation
242
Rear Upper A-Arm Removal
242
Rear Lower A-Arm Removal
243
Rear Lower A-Arm Installation
244
Exploded View
245
Rear Stabilizer Bar / Linkage
245
Removal / Installation
246
Decal Replacement
247
Exploded View
248
Shock Removal / Installation
248
Shock Replacement
248
Shocks / Springs
248
Chapter 6 Clutching
250
Pvt System Fastener Torques
252
Special Tools and Supplies
252
Torque Specifications
252
Clutch Chart
253
High Altitude Clutch Charts
253
Drive Clutch Operation
254
Driven Clutch Operation
254
General Operation
254
Pvt System Overview
254
Maintenance / Inspection
255
Pvt Break-In (Drive Belt / Clutches)
255
Overheating / Diagnosis
256
Pvt Covers and Ducting Components
257
Pvt System Service
257
Pvt Disassembly
258
Pvt Assembly
260
Belt Removal
262
Drive Belt
262
Belt Inspection
263
Belt Installation
263
Pvt Break-In (Drive Belt / Clutches)
263
Drive Clutch Exploded View
264
Drive Clutch Service
264
Bearing Inspection
265
Clutch Disassembly
265
Drive Clutch Spring Inspection
266
Shift Weight Inspection
266
Button to Tower Clearance Inspection
267
Spider Removal
267
Clutch Inspection
268
Roller, Pin, and Thrust Washer Inspection
268
Moveable Sheave Bushing Inspection
269
Bushing Service
270
Clutch Assembly
272
Clutch Disassembly / Inspection
274
Driven Clutch Service
274
Exploded View
274
Clutch Assembly
276
2014 Driven Clutch Service (Non-Ebs)
278
Clutch Disassembly / Inspection 2014 (Non-Ebs)
278
Exploded View 2014 (Non-Ebs)
278
Clutch Assembly 2014 (Non-Ebs)
279
2014 Driven Clutch Service (Ebs)
280
Exploded View 2014 (Ebs)
280
Clutch Disassembly (Ebs)
281
Clutch Inspection
282
Clutch Assembly 2014 (Ebs)
283
Troubleshooting
286
Chapter 7 Final Drive
288
Special Tools
289
Torque Specifications
289
Bearing Carrier Inspection / Removal
290
Front Bearing Carrier
290
Bearing Replacement
291
Bearing Carrier Installation
292
Front Drive Shaft
294
Installation
294
Removal
294
Front Propshaft
295
Removal / Installation
295
Removal / Installation - Crew
295
Disassembly
297
Propshaft U-Joint Service
297
Assembly
298
Centralized Hilliard Exploded View
299
Front Gearcase - Centralized Hilliard
299
All Wheel Drive Operation
300
Awd Diagnosis
301
Front Gearcase Removal
301
Front Gearcase Disassembly / Inspection
302
Front Gearcase Assembly
306
Front Gearcase Installation
308
Inspection
310
Rear Bearing Carrier
310
Removal
310
Bearing Replacement
311
Installation
313
Rear Drive Shaft
313
Removal
313
Drive Shaft / CV Joint Handling Tips
314
Drive Shaft Service
314
Outer CV Joint / Boot Replacement
314
Inner Plunging Joint / Boot Replacement
316
Drive Shaft Cutaway View
319
Chapter 8 Transmission
320
Lubrication
321
Special Tools
321
Specifications
321
Torque Specifications
321
Transmission Mounting and Torque Values
322
Removal / Installation
323
Shift Lever
323
Adjustment
324
Inspection
324
Shift Cable
324
Transmission Removal
325
Transmission Installation
329
Differential Operation
333
Transmission Service
333
Transmission Disassembly
334
Planetary Differential Disassembly
339
Planetary Differential Bushing Replacement
340
Planetary Differential Assembly
342
Gear / Shaft / Bearing Inspection
343
Snorkel Gear Backlash Procedure
344
Troubleshooting
350
Troubleshooting Checklist
350
Exploded View
351
Transmission Exploded View
351
Chapter 9 Brakes
354
General Specifications
356
Brake System Service Notes
358
Brake Noise Troubleshooting
359
Hydraulic Brake System Operation
360
Brake System Assembly View
361
Installation
362
Master Cylinder
362
Removal
362
Foot Brake Pedal
363
Installation
363
Removal
363
Brake Bleeding / Fluid Change
364
Front Brake Pads
366
Pad Removal
366
Pad Assembly / Installation
367
Pad Inspection
367
Brake Burnishing Procedure
368
Caliper Exploded View
369
Caliper Removal
369
Front Caliper Service
369
Caliper Disassembly
370
Caliper Inspection
371
Caliper Assembly
372
Caliper Installation
372
Disc Inspection
374
Disc Runout
374
Front Brake Disc
374
Disc Removal / Replacement
375
Pad Inspection
376
Pad Removal
376
Rear Brake Pads
376
Brake Burnishing Procedure
377
Pad Installation
377
Caliper Exploded View
378
Rear Caliper Service
378
Caliper Exploded View Ranger Crew
379
Caliper Disassembly
380
Caliper Removal
380
Caliper Assembly
381
Caliper Inspection
381
Caliper Installation
382
Disc Inspection
383
Disc Runout
383
Rear Brake Disc
383
Disc Removal / Replacement
384
Brakes Lock
385
Caliper Overheats (Brakes Drag)
385
Pedal Vibration
385
Troubleshooting
385
Chapter 10 Electrical
386
Components Behind Dash Panel
388
Components under Hood
388
Components under Passenger Seat Base
388
Electrical Service Notes
388
General Information
388
Special Tools
388
Brake Light Switch
389
Headlamp Switch
389
Switches / Controls
389
Awd / 2Wd / Turf Switch
390
Ignition Key Switch
390
Transmission (Gear Position) Switch
391
Speed Sensor Location
392
Speed Sensor Testing
392
Vehicle Speed Sensor
392
Differential Solenoid Circuit Operation
393
Differential Solenoid Overview
393
Rear Diff Solenoid
393
Instrument Cluster
395
Overview
395
Rider Information Display
396
Information Display Area
397
Diagnostic Mode
399
Instrument Cluster Removal
400
Instrument Cluster Installation
401
All Wheel Drive Coils
402
Audio System (Le Only)
402
Diagnosing System Failures
402
Operation Overview
402
Headlight Adjustment
403
Headlight Bulb Replacement
403
Headlights
403
Headlight Housing Installation
404
Headlight Housing Removal
404
Led Lamp Replacement
406
Tail Light / Brake Light
406
Efi Component Information / Testing
407
Efi Diagnostics
407
Fuel Sender
407
Testing
407
Cooling System
408
Cooling System Break-Out Diagram
408
Coolant Temperature Sensor
409
Fan Control Circuit Bypass Test
409
Fan Control Circuit Operation / Testing
409
Fuse Box: Fuses / Relays / Circuit Breaker
410
Overview / Operation
410
Fuse Box Detail
411
Relay Operation
412
Charging System
414
Charging System "Break Even" Test
414
Charging System Stator (Alternator) Tests
414
Current Draw - Key off
414
Stator (Alternator) Replacement
415
Regulator / Rectifier
416
Charging System Testing Flow Chart
417
Battery Service
418
Battery Specifications
418
Battery Terminal Block
418
General Battery Information
418
Battery Conductance Analyzer
419
Battery off Season Storage
419
Battery Removal / Installation
419
Battery Testing
419
Load Test
419
Ocv - Open Circuit Voltage Test
419
Battery Charging Procedure
420
Starter Motor Removal
421
Starter System
421
Troubleshooting
421
Voltage Drop Test
421
Starter Motor Installation
422
Starter Solenoid Bench Test
422
Starter Solenoid Operation
422
Starting System Testing Flow Chart
424
Electronic Power Steering (Eps)
425
Eps Operation
425
Proper Eps System Diagnosing
425
Eps System Breakout
426
Eps Troubleshooting (Power Steering Non-Functional with Mil On)
427
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
428
Eps Troubleshooting (Using Digital Wrench®)
429
4
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Polaris RANGER CREW 900 2014 Specifications
General
Brand
Polaris
Model
RANGER CREW 900 2014
Category
Offroad Vehicle
Language
English
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