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RANGER XP 1000 2018
Polaris RANGER XP 1000 2018 User Manual
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1
1
9928487
R01
-
2018
RANGER
XP
1000
Service
Manual
©
Copyright
Polaris
Industries
Inc.
1
1.25
COOLING
SYSTEM
SERVICE
COOLING
SYSTEM
BREAK-OUT
DIAGRAM
ELECTRICAL
520
522
Table of Contents
Safety Warnings
2
Trademarks
3
Revision Index
3
2018 Vehicle Updates
3
Chapter Summary
4
General Information/Contents
5
Reference Information
6
Service Rules
6
Publication Part Numbers
7
Replacement Keys
7
Special Tools Website
8
Special Tools Index
9
Master Torque List
15
Vehicle Identification Number (VIN) Designation
22
Model Number Designation
22
Engine Designation Number
22
Vehicle and Engine Serial Number Location
22
Vehicle Specifications
23
2018 Ranger XP 1000 Specifications
24
MISC. Specifications and Charts
25
Conversion Table
25
Standard/Metric Bolt Torque Specification
26
Sae/Metric Tap/Drill Sizes
27
Sae Tap / Drill Sizes
27
Decimal Equivalents
28
Maintenance/Contents
29
Maintenance Service Notes
31
Maintenance Special Tools
31
Service Specifications - Maintenance
32
Periodic Maintenance Overview
33
Break-In Period
33
Severe Use Definition
33
Pre-Ride Inspection
34
Maintenance Intervals
35
25 Hour/250 Mile (400 Km) Service
35
50 Hour/500 Mile (800 Km) Service
36
75 Hour/750 Mile (1200 Km) Service
37
100 Hour/1000 Mile (1600 Km) Service
38
120 Hour/1250 Mile (2000 Km) Service
39
150 Hour/1500 Mile (2400 Km) Service
40
175 Hour/1750 Mile (2800 Km) Service
41
200 Hour/2000 Mile (3200 Km) Service
42
225 Hour/2250 Mile (3600 Km) Service
43
250 Hour/2500 Mile (4000 Km) Service
44
275 Hour/2750 Mile (4400 Km) Service
45
300 Hour/3000 Mile (4800 Km) Service
46
325 Hour/3250 Mile (5200 Km) Service
47
350 Hour/3500 Mile (5600 Km) Service
48
375 Hour/3750 Mile (6000 Km) Service
49
400 Hour/4000 Mile (6400 Km) Service
50
425 Hour/4250 Mile (6400 Km) Service
51
450 Hour/4500 Mile (6800 Km) Service
52
475 Hour/4750 Mile (7200 Km) Service
53
500 Hour/5000 Mile (7600 Km) Service
54
Maintenance Quick Reference
55
Maintenance
56
Grease Lubrication Points
57
Maintenance Lubricants
58
Polaris Lubricants, Maintenance and Service Products
59
General Vehicle Inspection and Maintenance
60
Pre-Ride/Daily Inspection
60
Frame, Nuts, Bolts and Fasteners
60
Engine Maintenance
61
Engine Oil Level Inspection
61
Engine Oil and Filter Replacement
62
Engine Crankcase Breather Hose Inspection
63
Engine Cylinder Leakdown Test
63
Valve Clearance Inspection
64
Cam Chain Tensioner Inspection
66
Liquid Cooling System Overview
67
Coolant Strength/Type
67
Coolant Level Inspection
67
Cooling System Hose Inspection
68
Radiator Inspection
69
Coolant Replacement
69
Air Intake and Exhaust Maintenance
70
Air Filter Replacement
70
Exhaust Spark Arrestor Inspection
71
Exhaust Heat Shield Inspection
72
Fuel System Maintenance
73
Fuel Line/Pump/Filter Inspection
73
Fuel Tank Vent Line Inspection
74
PVT System Maintenance
75
Drive Belt Inspection
75
PVT System Drying
75
Transmission and Front Gearcase Maintenance
76
Transmission Fluid Level Inspection
76
Transmission Fluid Replacement
76
Shift Cable Inspection/Adjustment
77
Front Gearcase Fluid Level Inspection
77
Front Gearcase Fluid Replacement
78
Final Drive Maintenance
79
Drive Shaft Boot Inspection
79
Wheel Replacement
79
Tire Inspection
80
Tire Pressure Inspection
80
Steering Maintenance
81
Steering System Inspection
81
Steering Wheel Free-Play
81
Tie Rod End Inspection
82
Wheel Toe Inspection
82
Wheel Toe Adjustment
83
Suspension Maintenance
84
Suspension Inspection
84
Shock Position Adjustment
84
Brake System Maintenance
85
Brake Fluid Level Inspection
85
Brake Fluid Replacement/Brake Bleeding
85
Brake Pad/Disc Inspection
87
Brake Hose and Fitting Inspection
87
Electrical Maintenance
88
Battery Maintenance/Replacement
88
Chassis/Engine Electrical Ground
89
Spark Plug Replacement
90
Throttle Pedal Inspection
91
Engine/Cooling/Exhaust Contents
93
Special Tools - Engine/Cooling System
97
Engine Lubrication Specifications
97
Oil Pressure Test
98
Engine Oil Flow Chart
99
Engine Break-In Period
100
Engine Service Specifications
101
Engine Torque Specifications
103
Intake System Assembly View
105
Intake Manifold Removal
107
Intake Manifold Installation
109
Exhaust System Assembly View
111
Engine Service
112
Accessible Engine Components
112
Front Engine Mount Isolator Replacement
112
Engine Removal
113
Engine Removal (HVAC)
114
Engine Installation
116
Engine Installation (HVAC)
119
Engine Disassembly/Inspection - Top End
121
Valve Cover Removal
121
Camshaft Removal
121
Camshaft Sprocket Inspection
122
Camshaft/Camshaft Bore Inspection
123
Cylinder Head Removal
124
Cylinder Head Warp Inspection
125
Cylinder Head Disassembly
126
Valve Inspection
127
Combustion Chamber Cleaning
128
Valve Sealing Test
128
Valve Seat Reconditioning
129
Intake/Exhaust Seat Cutter Diameter
130
Engine Disassembly/Inspection - Lower End
132
Stator Cover Removal/Inspection
132
Water Pump Housing Removal
133
Flywheel Removal
134
Starter One-Way Clutch Inspection
134
Starter One-Way Clutch Disassembly
135
Crankcase Disassembly/Inspection
136
Balance Shaft Removal/Inspection
138
Crankshaft Removal/Inspection
139
Crankcase Inspection
141
Cylinder Inspection
142
Cylinder/Piston Removal
143
Piston Disassembly/Inspection
144
Piston Ring Removal
145
Piston Ring to Groove Clearance Inspection
145
Piston Ring Installed Gap
146
Piston-To-Cylinder Clearance
146
Connecting Rod Inspection
147
Bearing Selection Chart - Rod Bearings
148
Engine Assembly - Lower End
149
Bearing Selection Identification Letters and Numbers
149
Connecting Rod Bearing Selection
150
Crankshaft Main Bearing Selection
150
Bearing Selection Chart - Rod/Main Bearings
150
Upper Crankcase Preparation
151
Piston Ring Installation
151
Piston/Connecting Rod Assembly
153
Cylinder/Piston Installation
154
Crankshaft Installation
156
Balance Shaft Installation
157
Lower Crankcase Preparation
158
Crankcase Assembly
159
Starter One-Way Clutch Assembly
163
Flywheel Installation
164
Stator Cover Installation
164
Engine Assembly - Top End
165
Cylinder Head Assembly
165
Cylinder Head Installation
166
Camshaft Installation/Timing
168
Timing View for Sprockets/Camshafts
169
Camshaft Timing - Quick Reference
172
Valve Clearance Adjustment
173
Valve Lash - Tappet Selection
175
Available Tappets
175
Valve Cover Installation
176
Cooling System Service
177
Cooling System Assembly View
177
Coolant Flow Diagram
177
Cooling System Specifications
178
Cooling System Pressure Test
178
Recommended Coolant
178
Radiator Cap Pressure Test
179
Radiator Removal/Installation
180
Radiator Fan Removal
181
Thermostat Replacement
182
Cooling System Bleeding Procedure
183
Water Pump Removal
185
Water Pump Installation
186
Water Pump Service
187
Water Pump Assembly View
189
Troubleshooting - Engine
190
Cooling System Troubleshooting
191
HVAC System Fastener Torques
192
Special Tools - HVAC
192
HVAC System Timing
192
HVAC System Overview
193
Air Conditioning Description
193
HVAC Assembly View
194
HVAC and Heater Lines
194
HVAC Ducting
195
A/C System Diagram
196
Safety Equipment
197
HVAC System Components
197
HVAC Maintenance
200
Compressor Drive Belt Inspection
200
A/C Condenser Cleaning
201
HVAC Filter Inspection/Replacement
202
Refrigerant
202
Reclamation and Charging with Recovery/Charging Unit
203
HVAC System Service
204
Compressor Drive Belt Replacement
204
Service Video
204
Compressor Replacement
206
Compressor Oil Specifications
206
Compressor Oil Inspection
207
Alternator Inspection/Replacement
208
HVAC Cover Mount Replacement
209
Condenser Replacement/Removal
210
Condenser Installation
211
High Pressure Cut-Out (HPCO) Switch Overview
213
HPCO Switch Replacement
213
Expansion Valve/Evaporator Coil Replacement
213
Heater/Evaporator Unit Replacement/Removal
214
Heater/Evaporator Unit Installation
215
Heater Coil Replacement
216
Blower Unit Replacement
216
A/C Thermostat Overview
217
Heater Valve Replacement
217
HVAC Control Service
218
HVAC Control Operation Overview
218
A/C/Fan Switch Testing
218
Temperature Potentiometer Testing
218
HVAC Breakout Diagram
219
Teoubleshooting - HVAC
220
Blower Motor Does Not Operate
220
Blower Motor Operates Normally but Air Flow Is Insufficient
220
Insufficient Cooling (Air Flow and Compressor Operation Are Normal)
220
Gauge Pressure Related Troubleshooting
221
Temperature/Pressure Chart
222
Evaporator
222
Condenser
222
Poor A/C Performance
223
Engine Coolant Bypassing the Heater Valve
223
Fuel System/Contents
225
Service Notes - Fuel System
227
Special Tools - Fuel System
228
Fuel Pressure Gauge Kit - PU-43506-A
228
Fuel Pressure Gauge Adapter - PS-48762
228
Digital Wrench Diagnostic Kit - PU-47063-B
228
Service Specifications - Fuel System
229
Digital Wrench Smartlink Module Kit - PU-47471
229
Digital Wrench - Diagnostic Connector
229
Digital Wrench - Download Website
229
Electronic Fuel Injection
230
Fuel System Operation Overview
230
Initial Priming/Starting Procedure
230
Fuel System Components
230
Fuel System Component Locations
231
Fuel Line Routing
233
Fuel Line Removal/Installation
234
Fuel Vent Line Routing
235
Fuel Vent Line Routing (EVAP Models)
236
Vent Line Termination Fitting
237
Fuel Line Quick Connect Removal
238
Fuel Tank Service
240
Fuel Tank Assembly View
240
Fuel Flow
240
Fuel Tank Removal
241
Fuel Tank Installation
242
Fuel Pump Service
245
Operation Overview
245
Fuel Sender Test
245
Fuel Pump Test
246
Fuel Pump Replacement
247
Electronic Control Unit (ECU)
250
ECU Operation Overview
250
ECU Service
250
ECU Replacement
251
ETC Learn Procedure
251
Electronic Throttle Control (ETC)
252
ETC Operation Overview
252
ETC Test/Replacement
252
Throttle Control Switch
253
Drive Mode Switch Description and Operation
253
Throttle Control Switch Replacement
254
Crankshaft Position Sensor (CPS)
255
CPS Operation Overview
255
CPS Test/Connector
255
CPS Replacement
256
ECT Sensor Replacement
259
Pedal Position Sensor (PPS)
260
PPS Operation Overview
260
PPS Test/Replacement
260
Fuel Injector Service
261
Fuel Injector Operation Overview
261
Fuel Injector Troubleshooting
261
Fuel System Diagnosis
265
Instrument Cluster Trouble Code Display
265
Diagnostic Trouble Code Table
266
Cylinder Misfire Detection
270
Fuel System Troubleshooting
271
Digital Wrench Operation
272
Digital Wrench Diagnostic Software Overview
272
Special Tools
272
Diagnostic Software Version
272
Digital Wrench Communication/Diagnostic
273
Digital Wrench Serial Number Location
274
Digital Wrench Version and Update ID
274
Digital Wrench Updates
274
Digital Wrench Feature Map
276
Engine Controller Programming (Reflash)
277
Polaris Mobile Digital Wrench (PMDW)
280
PVT System/Contents
281
Service Notes - PVT System
283
Special Tools - PVT System
283
Service Specifications - PVT System
284
Clutch Chart
284
PVT System Overview
285
Drive/Driven Clutch Operation
285
PVT Break-In (Drive Belt/Clutches)
285
Maintenance/Inspection
285
Drive Belt Service
286
Belt Removal
286
Belt Inspection
287
Belt Installation
288
Driven Clutch Alignment
289
PVT System Service
290
PVT Covers and Ducting Assembly View
290
PVT Duct Removal/Install
291
Outlet/Inlet Duct Removal/Installation
291
PVT Inner Cover Disassembly
292
PVT Inner Cover Assembly
293
Drive Clutch Service
298
Drive Clutch Assembly View
298
Clutch Disassembly
300
Bearing Inspection
300
Button to Tower Clearance Inspection
301
Spider Removal
301
Roller, Pin and Thrust Washer Inspection
301
Shift Weight Inspection
302
Clutch Inspection
302
Drive Clutch Spring Inspection
304
Drive Clutch Bushing Inspections
305
Bushing Service
305
Moveable Sheave - Bushing Removal
305
Drive Clutch Bushing Installation
306
Cover Bushing Removal/Installation
306
Clutch Assembly
307
One-Way Bearing Bushing Replacement
307
Driven Clutch Service
310
Driven Clutch Assembly View
310
Driven Clutch Disassembly (EBS)
311
Helix and Movable Sheave Bushing Inspection
312
Movable Sheave Bushing Removal/Installation
312
Helix Bushing Removal/Installation
313
Driven Clutch Assembly
314
Troubleshooting
315
Overheating/Diagnosis
318
Clutch Drive Belt and Cover Related Issues: Diagnosis
318
Operating in Low Gear
318
Transmission/Contents
321
Service Notes - Transmission
322
Special Tools - Transmission
322
Service Specifications - Transmission
322
Transmission Assembly View
323
Transmission Vent Line Routing
324
Shift Cable Service/Inspection
325
Shift Lever Removal/Installation
325
Shift Cable Adjustment
326
Transmission Service
327
Differential Operation
327
Transmission Removal
329
Transmission Installation
332
Transmission Disassmebly
335
Gear Cluster Disassembly
337
Snorkel Tube Removal/Disassembly
337
Planetary Differential Disassembly
339
Planetary Differential Bushing Replacement
340
Ring Gear Bushing Replacement
340
Planet Gear Bushing Replacement
340
Differential Cover Bushing Replacement
341
Female Side Gear Bushing Replacement
341
Planetary Differential Assembly
342
Gear, Shaft, Bearing Inspection
343
Snorkel Gear Backlash Procedure
344
Transmission Assembly
346
Troubleshooting - Transmission
351
Final Drive/Contents
353
Service Notes - Final Drive
355
Special Tools - Final Drive
355
Service Specifications - Final Drive
355
Front Gearcase Vent Line Routing
356
Front Bearing Carrier Service
357
Bearing Carrier Removal/Inspection
357
Bearing Replacement/Removal/Installation
358
Bearing Carrier Installation
359
Front Drive Shaft Service/Removal/Installation
361
Prop Shaft Service
362
Front Prop Shaft Removal
362
Front Prop Shaft Installation
365
Rear Prop Shaft Removal/Installation
368
Propshaft U-Joint Service/Disassembly
369
Propshaft U-Joint Assembly
370
Front Gearcase Service
372
Front Gearcase Assembly View
372
All Wheel Drive (AWD) Operation
373
All Wheel Drive (AWD) Diagnosis
374
AWD will Not Engage
374
Front Gearcase Removal/Disassembly/Inspection
375
Front Gearcase Assembly
378
Front Gearcase Installation
381
Front Gearcase (ADC) Operation
382
Front Gearcase (ADC) Disassembly/Inspection
383
Front Gearcase (ADC) Reassembly
386
Front Gearcase (ADC) Troubleshooting
389
Rear Bearing Carrier Service/Inspection/Removal
392
Rear Bearing Carrier Bearing Replacement
393
Rear Bearing Carrier Installation
394
Rear Drive Shaft Service/Removal
395
Rear Drive Shaft Installation
396
Drive Shaft Service
397
Drive Shaft Cutaway View
397
Drive Shaft/CV Joint Handling Tips
397
Outer CV Joint/Boot Replacement
398
Inner Plunging Joint/Boot Replacement
400
Steering and Suspension/Contents
403
Service Notes - Steering/Suspension
404
Special Tools - Steering/Suspension
404
Service Specifications - Steering/Suspension
404
Steering Assembly Service/View
405
Steering Wheel/Upper Steering Shaft Removal
406
Steering Rack Removal
407
Steering Rack Installation
408
Steering Shaft Bearing Replacement
409
Power Steering Unit Installation
410
Steering Inspection
411
Tie Rod End/Wheel Hub Inspection
412
Front A-Arm Service
414
Front Lower A-Arm Removal/Installation
414
A-Arm Bushing Replacement
415
Front Upper A-Arm Removal/Installation
415
Ball Joint Service Preparation
417
Ball Joint Removal
418
Ball Joint Installation
419
Rear A-Arm Service
420
Rear Upper A-Arm Removal
420
Rear Upper A-Arm Installation
421
Rear Lower A-Arm Removal
422
Stabilizer Bar Service
423
Rear Lower A-Arm Installation
423
Rear Stabilizer Bar Removal/Installation
423
Shock/Spring Service
424
Shock Removal/Installation
424
Shock Spring Replacement
424
Brake System/Contents
425
Service Notes - Brake System
427
Special Tools - Brake System
427
Service Specifications - Brake System
428
Brake System Assembly View
429
Brake Line Routing
430
Front Brake Lines from Calipers to Master Cylinder
430
Rear Brake Line from Master Cylinder to Junction Block
431
Rear Brake Lines from Junction Block to Rear Calipers
431
Brake Line Clocking
432
Master Cylinder Service/Removal
435
Master Cylinder Installation
436
Brake Pedal Replacement
437
Front Brake Pad Service/Removal
438
Front Brake Pad Inspection/Installation
439
Brake Burnishing Procedure
440
Front Caliper Assembly View
441
Front Caliper Removal
442
Front Caliper Disassembly
443
Front Caliper Inspection/Assembly
444
Front Caliper Installation
445
Front Brake Disc Service
446
Disc Runout
446
Brake Disc Inspection
446
Rear Brake Pad Service/Removal
448
Rear Brake Pad Inspection/Installation
449
Rear Caliper Assembly View
451
Rear Caliper Removal
452
Rear Caliper Disassembly
453
Rear Caliper Assembly/Inspection
454
Rear Caliper Installation
455
Rear Brake Disc Service
456
Brake Disk Inspection
456
Brake Disc Replacement
457
Brake Noise Troubleshooting
458
Brakes Squeal/Poor Brake Performance
458
Pedal Vibration
458
Caliper Overheats (Brakes Drag)
458
Body and Frame/Contents
459
Service Notes - Body/Frame
461
Special Tools - Body/Frame
461
Decal Replacement
461
Body Components Assembly Views
462
Chassis Assembly View
462
Dash Panel/Glove Box Assembly View
463
Front Body Assembly View
465
Floors/Fender Assembly View
466
Seat Components Assembly View
468
Cab Frame Assembly View
470
Door Assembly View
471
Roof Assembly View
472
Rear Panel Assembly View
476
Cargo Box Assembly View
477
Tailgate Assembly
477
Cargo Box Assembly
478
Cargo Box Frame Assembly
479
Cab Frame Service
480
Door and Roof Removal/Installation
480
Rear Panel Removal/Installation
481
Rear Cargo Box Service
482
Cargo Box Removal/Installation
482
Body Component Service
483
Driver's Seat Removal
483
Front Bumper Removal
483
Front Fender Service
484
Upper Fender Removal/Installation
484
Lower Fender Service
485
Lower Fender Installation
486
Front Fascia Service/Removal
487
Front Fascia Installation
488
Dash Panels/Glove Box Removal
489
Upper Dash Removal
489
Lower Dash Panel Removal
491
Rocker Panel Removal
492
Floor Removal
493
Floor Installation
494
Accessory Service
495
Electrical/Contents
497
Service Notes - Electrical
500
Special Tools - Electrical
501
Service Specifications - Electrical
501
Switches/Control Service
502
Brake/Headlamp Switch
502
Ignition Key Switch
503
Awd/2Wd/Turf Switch
503
Transmission (Gear Position) Switch
504
Seat Belt Switch
504
Deive Mode Switch
505
Digital Wrench Values
505
Vehicle Speed Sensor Service
506
Speed Sensor Location/Testing
506
Rear Diff Solenoid Service
507
Differential Solenoid Overview
507
Differential Solenoid Circuit Operation
507
Differential Solenoid Replacement
508
Instrument Cluster Overview
509
Speedometer
510
Tachometer
510
Mode and Toggle Buttons
510
Indicator Lamps
510
Rider Information Center
511
Mode Information Displays
511
Accessing Menus and Options
512
Gauge Settings Menu
512
Backlight Color/Brightness
512
Clock
512
Display Units (Standard/Metric)
513
Trip Meter/Time
513
Programmable Service Interval
513
Engine Error Codes
514
Instrument Cluster Pinouts
514
Instrument Cluster Service
515
All Wheel Drive Coil Service
516
Diagnosis System Failures
516
Headlight Service/Adjustment
517
Headlight Bulb Replacement
519
Headlight Housing Removal
519
Headlight Housing Installation
520
Tail Light Service
520
Cooling System Break-Out Diagram
521
Fan Control Circuit Operation/Testing
522
Fan Control Circuit Bypass Test
522
Coolant Temperature Sensor
522
Ignition Coil Service
523
Ignition Coil Operation Overview
523
Ignition Coil/ HT Lead Replacement
523
Primary/Secondary Ignition Coil Tests
524
Ignition Coil Resistance Readings
524
Fuses/Relays/Circuit Break Service
525
Fuse Box Operation Overview
525
Relay Operation
527
Rear Diff Solenoid Relay
528
Charging System Service
529
Current Draw - Key off
529
Charging System "Break Even" Test
529
Charging System Stator (Alternator) Tests
530
Stator Replacement
530
Alternator Replacement
531
Regulator/Rectifier Replacement
533
Charging System Testing Flow Chart
534
Electrical Diagnostics
535
Electrical Service Notes
535
Digital Multi-Meter (DMM) Notes
535
Static and Dynamic Testing
535
Connector Probing Guidelines
536
Front/Back Probing
536
Break out
536
Testing Continuity/Resistance
537
Testing for a Short to Ground
538
Testing for a Short to Voltage
539
Testing for Intermittent Conditions
539
Testing Current Flow (Amperage)
540
Testing Parasitic Draw
540
Testing Voltage Drop
541
Battery Specifications
542
General Battery Information
542
Battery Service
542
Battery Terminal Block
543
Battery off Season Storage
543
Battery Testing
543
Open Circuit Voltage and Load Test
543
Battery Conductance Analyzer
544
Battery Charging Procedure
544
Starter System Service
545
Voltage Drop Test
545
Starter Motor Removal
545
Starter Motor Installation
546
Starter Solenoid Bench Test
546
Starter Solenoid Operation
547
Starting System Testing Flow Chart
548
Electronic Power Steering (EPS)
549
EPS Operation
549
Proper EPS System Diagnosing
549
EPS Torque Offset Procedure
549
EPS System Breakout
550
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
Index
555
Chassis Schematic - BASE 2018-Ranger XP 1000
563
Chassis Schematic - HVAC 2018-Ranger XP 1000
564
Cargo Box Schematic - 2018-Ranger XP 1000
565
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Polaris RANGER XP 1000 2018 Specifications
General
Brand
Polaris
Model
RANGER XP 1000 2018
Category
Utility Vehicle
Language
English
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