2018-2019 Polaris Ranger XP 1000 Service & Repair Manual

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 November 2017 (PN 9928487 R01) © Copyright 2017 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 RANGER XP 1000 Service Manual

SAFETY WARNINGS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE NOTE provides key information by clarifying instructions. IMPORTANT IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. REVISION INDEX REV DATE CHANGES R01 11/28/17 Initial release 2018 VEHICLE UPDATES APPLICABLE MODEL UPDATE DESCRIPTION XP 1000 Models All New Vehicle For more detailed information on vehicle updates, refer to the applicable Model Year Update training module at: www.mytrainingandrewards.com .

2018 RANGER XP 1000 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING / EXHAUST CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM CHAPTER 10: BODY / FRAME CHAPTER 11: ELECTRICAL

1 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc. 1.1 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION REFERENCE INFORMATION ........................................................................... 1.2 SERVICE RULES...................................................................................... 1.2 PUBLICATION PART NUMBERS ...................................................................... 1.3 REPLACEMENT KEYS ................................................................................ 1.3 SPECIAL TOOLS WEBSITE ........................................................................... 1.4 SPECIAL TOOLS INDEX............................................................................... 1.5 MASTER TORQUE LIST.............................................................................. 1.11 VEHICLE IDENTIFICATION ............................................................................ 1.18 MODEL NUMBER DESIGNATION .................................................................... 1.18 VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION........................................... 1.18 ENGINE DESIGNATION NUMBER.................................................................... 1.18 VEHICLE AND ENGINE SERIAL NUMBER LOCATION................................................ 1.18 VEHICLE SPECIFICATIONS ........................................................................... 1.19 2018 RANGER XP 1000 OVERVIEW ................................................................. 1.19 2018 RANGER XP 1000 SPECIFICATIONS ........................................................... 1.20 MISC. SPECIFICATIONS AND CHARTS .............................................................. 1.21 CONVERSION TABLE ................................................................................ 1.21 STANDARD BOLT TORQUE SPECIFICATION ........................................................ 1.22 METRIC BOLT TORQUE SPECIFICATION ............................................................ 1.22 SAE TAP / DRILL SIZES .............................................................................. 1.23 METRIC TAP / DRILL SIZES .......................................................................... 1.23 DECIMAL EQUIVALENTS ............................................................................ 1.24

1.2 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc. REFERENCE INFORMATION SERVICE RULES In order to perform service work efficiently and prevent costly errors, technicians should read the text in this manual and familiarize themselves with the procedures before beginning. Notes, Cautions and Warnings have been included for clarification of text and safety concerns. Knowledge of mechanical theory, tool use and shop procedures are necessary to perform some procedures in this manual safely and correctly. Use only genuine Polaris service parts, including fasteners that require replacement if removed. Do NOT substitute fasteners or hardware. Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will cause damage to precision parts. Clean the vehicle before beginning service. Clean all parts before installing. If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly. Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious machine damage or in the case of steering, driveline, and chassis components, can result in loss of control during operation of the vehicle, which may result in severe personal injury or death. If a torquing sequence is indicated for nuts, bolts or screws of a certain component, start all fasteners and hand tighten. Following the method and sequence indicated, tighten evenly to the specified torque value. When removing nuts, bolts or screws from a component with several fasteners, loosen them all about 1/4 turn before removing them to prevent distortion of that component. Replace all oil seals, sealing washers, gaskets, and O-rings with new ones during assembly. Be sure the mating surfaces for the gasket are clean and smooth to avoid leaks and maintain specified tolerances. Some procedures require removal of retaining rings or clips. Removal can weaken and deform these parts, therefore, they should always be replaced with new parts. When installing new retaining rings and clips, use care not to expand or compress them beyond what is required for installation. Polaris lubricants and greases have been specially formulated to provide maximum performance and protection when applied properly. In some applications, warranty coverage may be void if improper lubricants are used. Parts requiring grease should be cleaned thoroughly and fresh grease applied before reassembly. Deteriorating grease loses lubricity and may contain abrasive foreign matter. Always replace locking hardware such as lock nuts or lock washers, fasteners that have pre-applied locking agent, or any other fasteners as noted in this service manual with genuine Polaris hardware from an authorized Polaris dealer. Working with batteries can be hazardous. Review all battery warnings and cautions. GENERAL INFORMATION

9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc. 1.3 PUBLICATION PART NUMBERS Some vehicle publications, such as the Owner’s Manual and Parts Manual are available on-line and can be downloaded from the Polaris website (www.polarisindustries.com). MODEL MODEL NUMBER OWNER’S MANUAL 2018 RANGER XP 1000 R18RRE99AS / BS, R18RRU99AS / BS 9928300 2018 RANGER XP 1000 R18RRS99C1 / CS 9928195 2018 RANGER XP 1000 R18RRE99F1 / N1, R18RRS99F1 9928196 NOTE When ordering service parts be sure to use the correct parts manual. REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. (i.e. In this example, the first two digits are 31 which would use key blank PN 4110141. SERIES# PART NUMBER 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 GENERAL INFORMATION 1

1.4 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc. SPECIAL TOOLS WEBSITE Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris.service-solutions.com/ GENERAL INFORMATION

9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc. 1.5 SPECIAL TOOLS INDEX MAINTENANCE Oil Filter Wrench PU-50105 Shock Spanner Wrench 2877408 ENGINE / COOLING / EXHAUST Oil Filter Wrench PU-50105 Oil Pressure Gauge PV-43531 Oil Pressure Gauge Adapter PU-52492 Engine Stand (2” Bore) PU-50624 Engine Stand Adapter (Mounts To The Engine) PU-50562 Engine Stand Sleeve Adapter (Use With 2” Bore Stand) PU-50625 GENERAL INFORMATION 1

1.6 9928487 R01 - 2018 RANGER XP 1000 Service Manual © Copyright Polaris Industries Inc. ENGINE / COOLING / EXHAUST Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand) PW-47054 Water Pump Mechanical Seal Installer PU-50564 Valve Spring Compressor Adapter PV-43513-A Flywheel Puller PA-49316 Piston Ring Compressor Pliers PV-43570-1 Valve Spring Compressor PV-1253 or PV-4019 Cylinder Holding & Camshaft Timing Plate PU-50563 Crank Seal Installation Tool PU-52493 GENERAL INFORMATION

2018-2019 Polaris Ranger XP 1000 Service & Repair Manual

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