2020-2021 Polaris Ranger 1000 Service Manual


File Format: PDF
File Size: 19.19 MB
Number of Pages: 610
Delivery Method: Instant Download Access your file immediately after purchase.


Model Covers:
2020-2021 Polaris Ranger 1000:
Ranger 1000 3 SEAT
Ranger 1000 CREW


Table of Contents:
- 2020-2021 RANGER 1000
- Foreword
- Feedback Form
- CHAPTER 1 : GENERAL INFORMATION
- REFERENCE INFORMATION
- Service Rules
- Publication Part Numbers
- Replacement Keys
- Special Tools Website
- Special Tools Index
- Master Torque List
- VEHICLE IDENTIFICATION
- Model Number Designation
- Vehicle Identification Number (VIN) Designation
- Vehicle and Engine Serial Number Location
- VEHICLE SPECIFICATIONS
- Model Specifications - 3 Seat
- Model Specifications - Crew
- General Diagnostics Information Overview
- Guided Symptom Diagnostic
- Guided Symptom References
- Engine and Drivability Diagnostic Procedures
- Engine Cranks but does Not Start
- No Crank No Start or Slow Crank
- Over Heating
- Warning Lights
- Engine Troubleshooting
- Cooling Troubleshooting
- DIGITAL WRENCH
- Digital Wrench® Software Overview
- Special Tools
- Guided Diagnostics
- Digital Wrench® Software Installation and Updates
- Digital Wrench® Communication Errors
- Digital Wrench® - Diagnostic Connector
- Digital Wrench® Serial Number Location
- Digital Wrench® Feature Map
- Engine Controller Reprogramming (Reflash)
- Polaris Mobile Digital Wrench® (PMDW)
- ENGINE ELECTRICAL DIAGNOSTICS
- Diagnostic Trouble Codes Overview
- Master Trouble Code List
- Cylinder Misfire Detection
- Fluid Leaks
- Fluid Inspection
- FUEL SYSTEM DIAGNOSTICS
- Fuel System Troubleshooting
- PVT SYSTEM DIAGNOSTICS
- PVT System Troubleshooting
- PVT System Overheating / Diagnosis
- TRANSMISSION DIAGNOSTICS
- Hard Shifting
- Transmission Isolation
- FINAL DRIVE DIAGNOSTICS
- All Wheel Drive (AWD) Concerns
- Driveshaft (Half Shaft) Diagnostics
- BRAKE SYSTEM DIAGNOSTICS
- BRAKE NOISE TROUBLESHOOTING
- Brake Vibration
- Caliper Overheats (Brakes Drag)
- Poor Brake Performance
- Brakes Lock
- STEERING / SUSPENSION DIAGNOSTICS
- EPS Troubleshooting (Power Steering Non-Functional with MIL ON)
- EPS Troubleshooting (Power Steering Non-Functional with MIL OFF)
- EPS Troubleshooting (Using Digital Wrench®)
- Shock Analysis
- ELECTRICAL DIAGNOSTICS
- Electrical Service Notes
- Digital Multi-Meter (DMM) Notes
- Static and Dynamic Testing
- Connector Probing Guidelines
- Testing Continuity / Resistance
- Testing For A Short To Ground
- Testing For A Short To Voltage
- Testing for Intermittent Conditions
- Testing Current Flow (Amperage)
- Current Draw - Key Off
- Testing Voltage Drop
- CHAPTER 2 : MAINTENANCE
- GENERAL INFORMATION - MAINTENANCE
- Service Notes - Maintenance
- Maintenance Specifications
- Service Products
- PERIODIC MAINTENANCE
- Periodic Maintenance Overview
- Break-In Period
- Pre-Ride Inspection
- Maintenance Intervals
- Maintenance Quick Reference
- Grease Lubrication Points
- ENGINE MAINTENANCE
- Engine Oil Level Inspection
- Engine Oil and Filter Service
- Valve Clearance Inspection
- Cam Chain Tensioner Inspection
- COOLING SYSTEM MAINTENANCE
- Liquid Cooling System Overview
- Coolant Strength / Type
- Coolant Level Inspection
- Cooling System Hose Inspection
- Radiator Inspection
- Coolant Replacement
- AIR INTAKE AND EXHAUST MAINTENANCE
- Air Filter Service
- Engine Crankcase Breather Hose Inspection
- Exhaust Spark Arrestor Inspection
- Exhaust Heat Shield Inspection
- FUEL SYSTEM MAINTENANCE
- Fuel Line Inspection
- Fuel Pump / Filter Inspection
- Fuel Tank Vent Line Inspection
- PVT SYSTEM MAINTENANCE
- Drive Belt Inspection
- PVT System Drying
- TRANSMISSION AND FRONT GEARCASE MAINTENANCE
- Transmission Fluid Level Inspection
- Transmission Fluid Replacement
- Shift Cable Inspection
- Shift Cable Adjustment
- Front Gearcase Fluid Level Inspection
- Front Gearcase Fluid Replacement
- FINAL DRIVE MAINTENANCE
- Drive Shaft Boot Inspection
- Wheel Service
- Tire Inspection
- Tire Pressure Inspection
- STEERING MAINTENANCE
- Steering System Inspection
- Steering Wheel Free-Play Inspection
- Tie Rod End Inspection
- Wheel Toe Measurement
- Wheel Toe Adjustment
- SUSPENSION MAINTENANCE
- Suspension Inspection
- Spring Pre-Load Adjustment
- BRAKE SYSTEM MAINTENANCE
- Brake Fluid Level Inspection
- Brake Fluid Replacement / Brake Bleeding
- Brake Pad Inspection
- Brake Disc Inspection
- Brake Hose and Fitting Inspection
- ELECTRICAL MAINTENANCE
- Battery Maintenance
- Lead Acid Conventional Battery Maintenance
- Dry Shipped AGM Battery Maintenance
- Lead Acid Low Maintenance Battery Maintenance
- AGM Low Maintenance Battery Maintenance
- Battery Service
- Chassis / Engine Electrical Ground
- Throttle Pedal Inspection
- CHAPTER 3 : ENGINE / COOLING / EXHAUST
- ENGINE SERVICE SPECIFICATIONS
- Engine Specifications
- Engine Torque Sequences
- Valve Lash - Tappet Selection
- Bearing Selection Identification Letters and Numbers
- Connecting Rod Bearing Selection
- Crankshaft Main Bearing Selection
- INTAKE SERVICE
- Intake System Assembly View
- Airbox Service
- Intake Duct Service
- Throttle Body Service
- Intake Manifold Service
- Intake Manifold Adapter Service
- EXHAUST SERVICE
- Exhaust System Assembly View
- Muffler Service
- Headpipe Service
- ENGINE SERVICE
- Accessible Engine Components
- Engine Mount Isolator Service
- Crankshaft PTO Seal Replacement
- Engine Removal & Installation
- Engine Timing
- ENGINE SERVICE - TOP END
- Valve Cover Service
- Valve Clearance Adjustment
- Cam Chain Tensioner Service
- Camshaft Sprocket Service
- Camshaft Service
- Camshaft Inspection
- Cylinder Head Removal and Installation
- Valve Service
- Valve Inspection
- Valve Seat Reconditioning
- Cylinder Head Inspection
- Combustion Chamber Cleaning
- ENGINE SERVICE - BOTTOM END
- Oil Filter Adapter Service
- Oil Sump Service
- Oil Pump Service
- Upper Crankcase Service
- Balance Shaft Service
- Crankshaft Service / Inspection
- Cylinder / Piston Service
- Crankcase Inspection
- Cylinder Inspection
- Piston Disassembly / Inspection
- Connecting Rod Inspection
- Stator Cover Service
- Flywheel Service
- Starter One-Way Clutch Service
- Starter One-Way Clutch Inspection
- COOLING SYSTEM SERVICE
- Cooling System Specifications
- Cooling System Assembly View
- Coolant Service
- Cooling System Pressure Test
- Radiator Cap Pressure Test
- Radiator Service
- Radiator Fan Removal
- Engine Oil Cooler Service
- Thermostat Replacement
- Water Pump Service
- Heater Valve Service
- TROUBLESHOOTING
- Oil Pressure Test
- Engine Cylinder Leakdown Test
- CHAPTER 4 : ENGINE ELECTRICAL
- ENGINE HARNESS
- Engine Harness Routing
- ELECTRONIC CONTROL UNIT (ECU)
- ECU Operation Overview
- ECU Service
- ECU Replacement
- CRANKSHAFT POSITION SENSOR (CPS)
- CPS Operation Overview
- CPS Test
- CPS Replacement
- ELECTRONIC THROTTLE CONTROL (ETC)
- ETC Operation Overview
- ETC Test
- ETC Replacement
- ETC Learn Procedure
- STARTER SYSTEM SERVICE
- Starter Solenoid Operation
- Starter Solenoid Bench Test
- Starter Motor Service
- Starting System Testing Flow Chart
- Voltage Drop Test
- Troubleshooting
- IGNITION SYSTEM SERVICE
- Ignition Coil
- Ignition Coil Operation Overview
- Ignition Coil Service
- Spark Plug
- Spark Plug Inspection
- Spark Plug Service
- Ignition System Testing
- TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
- TMAP Operation Overview
- T-MAP Sensor Replacement
- T-MAP Sensor Test
- ENGINE COOLANT TEMPERATURE SENSOR (ECT)
- ECT Operation Overview
- ECT Sensor Replacement
- ECT Resistance Values
- ECT Sensor Test
- OXYGEN SENSOR
- Oxygen Sensor Information
- Oxygen Sensor Service
- Oxygen Sensor Diagnostic Tips
- DRIVE MODE SWITCH
- Drive Mode Switch Description and Operation
- Drive Mode Switch Replacement
- ACCELERATOR POSITION SENSOR (APS)
- APS Operation Overview
- APS Replacement
- APS Test
- COOLING SYSTEM TESTING
- Cooling System Break-Out Diagram
- Fan Control Circuit Operation / Testing
- Fan Control Circuit Bypass Test
- CHAPTER 5 : FUEL SYSTEM
- GENERAL INFORMATION - FUEL SYSTEM
- Service Notes - Fuel System
- Fuel System Specifications
- ELECTRONIC FUEL INJECTION
- Fuel System Operation Overview
- Initial Priming / Starting Procedure
- Fuel System Components
- Fuel System Component Locations
- FUEL LINES
- Fuel Line Routing
- Fuel Line Quick Connect Removal
- Fuel Supply Line Service
- Vent Line Termination Fitting
- Fuel Vent Line Routing
- Fuel Vent Line Routing (EVAP Models)
- FUEL TANK
- Fuel Tank Assembly View
- Fuel Tank Service
- FUEL PUMP
- Operation Overview
- Fuel Sender Test
- Fuel Pressure Test
- Fuel Pump Replacement
- EVAP SYSTEM
- Carbon Canister Service
- Purge Valve Service
- FUEL INJECTOR
- Fuel Injector Operation Overview
- Fuel Injector Troubleshooting
- Fuel Injector Test
- Fuel Injector Service
- CHAPTER 6 : PVT SYSTEM
- GENERAL INFORMATION - PVT SYSTEM
- PVT Specifications
- Clutch Settings
- PVT SYSTEM OVERVIEW
- Drive Clutch Operation
- Driven Clutch Operation
- PVT Break-In (Drive Belt / Clutches)
- Maintenance / Inspection
- DRIVE BELT
- Drive Belt Service
- Driven Clutch Alignment
- PVT SYSTEM SERVICE
- PVT Covers and Ducting Assembly View
- PVT Clutch Cover Service
- Drive Clutch Removal / Installation
- Driven Clutch Removal / Installation
- Inner PVT Cover Service
- DRIVE CLUTCH SERVICE
- Drive Clutch Assembly View
- Drive Clutch Service
- Drive Clutch Inspection
- Roller Replacement
- Bushing Service
- DRIVEN CLUTCH SERVICE
- Driven Clutch Assembly View
- Driven Clutch Service
- Helix and Movable Sheave Bushing Inspection
- Bushing Service
- Vehicle Creeping
- CHAPTER 7 : TRANSMISSION
- GENERAL INFORMATION - TRANSMISSION
- Service Notes - Transmission
- Special Tools - Transmission
- Transmission Specifications
- SHIFT CABLE
- Shift Lever Removal / Installation
- Shift Cable Inspection
- Shift Cable Adjustment
- Shift Cable Routing
- Shift Cable Service
- TRANSMISSION SERVICE
- Transmission Assembly View
- Transmission Vent Line Routing
- Transmission Removal and Installation
- Transmission Disassembly
- Differential Operation
- Bevel Differential Disassembly
- Bevel Differential Assembly
- Gear, Shaft, Bearing Inspection
- Snorkel Gear Backlash Procedure
- Transmission Assembly
- CHAPTER 8 : FINAL DRIVE
- GENERAL INFORMATION - FINAL DRIVE
- Service Notes - Final Drive
- Final Drive Specifications (2020)
- Final Drive Specifications (2021+)
- Rear Hub Identification
- FRONT BEARING CARRIER SERVICE
- Bearing Carrier Removal / Inspection
- Bearing Replacement
- Bearing Carrier Installation
- PROP SHAFT SERVICE
- Prop Shaft Service
- Front Prop Shaft Service (CREW)
- Rear Prop Shaft Service (CREW)
- PROPSHAFT U-JOINT SERVICE
- Propshaft U-Joint Disassembly
- Propshaft U-Joint Assembly
- FRONT GEARCASE SERVICE 2020 Models
- Front Gearcase Assembly View
- Front Gearcase Removal
- Front Gearcase Disassembly / Inspection
- Front Gearcase Assembly
- Front Gearcase Installation
- FRONT GEARCASE SERVICE 2021+ Models
- Front Gearcase Assembly View
- Front Gearcase Removal
- Front Gearcase Disassembly (Non-ADC)
- Front Gearcase Inspection
- Front Gearcase Assembly (Non-ADC)
- Front Gearcase Installation
- Front Gearcase Vent Line Routing
- FRONT DRIVE OPERATION / TROUBLEHSOOTING
- All Wheel Drive (AWD) Operation
- All Wheel Drive (AWD) Diagnosis
- REAR BEARING CARRIER SERVICE
- Rear Bearing Carrier Inspection
- Rear Bearing Carrier Removal
- Rear Bearing Carrier Bearing Replacement
- Rear Bearing Carrier Installation
- REAR DRIVE SHAFT SERVICE
- Rear Drive Shaft Removal
- Rear Drive Shaft Installation
- DRIVE SHAFT SERVICE
- Drive Shaft / CV Joint Handling Tips
- Outer CV Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- CHAPTER 9 : STEERING / SUSPENSION
- GENERAL INFORMATION - STEERING / SUSPENSION
- Service Notes - Steering / Suspension
- Steering & Suspension Specifications
- STEERING & SUSPENSION ASSEMBLY VIEWS
- Steering Assembly View
- Front Suspension Assembly View
- Rear Suspension Assembly View
- STEERING ASSEMBLY SERVICE
- Steering Wheel / Upper Steering Shaft Removal
- Steering Rack Removal
- Steering Rack Installation
- Steering Shaft Bearing Replacement
- Power Steering Unit Installation
- Steering Inspection
- Tie Rod End / Wheel Hub Inspection
- Wheel Toe Measurement
- Wheel Toe Adjustment
- FRONT A-ARM SERVICE
- Front Lower A-Arm Removal / Installation
- A-Arm Bushing Replacement
- Front Upper A-Arm Removal / Installation
- BALL JOINT SERVICE
- Ball Joint Service Preparation
- Ball Joint Removal
- Ball Joint Installation
- REAR A-ARM SERVICE
- Rear Upper A-Arm Removal
- Rear Upper A-Arm Installation
- A-Arm Bushing Replacement
- Rear Lower A-Arm Removal
- Rear Lower A-Arm Installation
- STABILIZER BAR SERVICE
- Rear Stabilizer Bar Removal / Installation
- SHOCK / SPRING SERVICE
- Shock Analysis
- Shock Removal and Installation
- Shock Spring Replacement
- CHAPTER 10 : BRAKE SYSTEM
- GENERAL INFORMATION - BRAKE SYSTEM
- Service Notes - Brake System
- Brake System Specifications
- BRAKE SYSTEM SERVICE
- Brake System Assembly View
- Brake Line Routing
- Brake Line Clocking
- Brake Fluid Replacement / Brake Bleeding
- MASTER CYLINDER SERVICE
- Master Cylinder Removal
- Master Cylinder Installation
- Brake Pedal Replacement
- FRONT BRAKE PAD SERVICE
- Front Brake Pad Removal
- Front Brake Pad Inspection
- Front Brake Pad Installation
- Brake Burnishing Procedure
- FRONT CALIPER SERVICE
- Front Caliper Assembly View
- Front Caliper Removal
- Front Caliper Disassembly
- Front Caliper Inspection
- Front Caliper Assembly
- Front Caliper Installation
- REAR BRAKE PAD SERVICE
- Rear Brake Pad Removal
- Rear Brake Pad Inspection
- Rear Brake Pad Installation
- Brake Burnishing Procedure
- REAR CALIPER SERVICE
- Rear Caliper Assembly View
- Rear Caliper Removal
- Rear Caliper Disassembly
- Rear Caliper Inspection
- Rear Caliper Assembly
- Rear Caliper Installation
- BRAKE DISC SERVICE
- Brake Disk Inspection
- Disc Runout
- Brake Disc Replacement
- CHAPTER 11 : BODY / FRAME
- GENERAL INFORMATION - BODY / FRAME
- Service Notes - Body / Frame
- BODY ASSEMBLY VIEWS
- Chassis Assembly View
- Chassis Assembly View (CREW)
- ROPS Assembly View
- ROPS Assembly View (Crew)
- Dash Panel Assembly View
- Front Body Assembly View
- Floors and Bulkhead Assembly View
- Roof Assembly View
- Roof Assembly View (CREW)
- Rear Panel Assembly View
- Cargo Box Assembly View
- CAB FRAME SERVICE
- Windshield Service
- Tip-out Windshield Service
- Tip-out Windshield Adjustment
- Roof Service
- Headliner Service
- Headliner Service (CREW)
- EXTERIOR BODY SERVICE
- Front Bumper Service
- Front Fender Service
- Skid Plate Service
- Front Fascia Service
- Side Bezel Cover Service
- Side Bezel Service
- Rocker Panel Service
- Rear Close-Off Panel Service
- Decal Replacement
- CARGO BOX
- Cargo Box Service
- DOOR SERVICE
- Standard Door Panel Service
- Door Latch Service
- Window Regulator / Door Glass Service
- Door Removal / Installation
- INTERIOR BODY SERVICE
- Upper Dash Panel Service
- Lower Dash Panel Service
- Seat Back Service
- Lower Seat Base Removal
- Floor Panel Service
- Roof Removal / Installation
- Rear Panel Removal / Installation
- Accessory Service
- CHAPTER 12 : CHASSIS / BODY ELECTRICAL
- GENERAL INFORMATION - ELECTRICAL SYSTEM
- Service Notes - Electrical
- Body Electrical Specifications
- FUSE BOX / CIRCUIT PROTECTION
- Fuse Box Breakout
- Relay Operation
- VEHICLE HARNESS SERVICE
- Chassis Harness Routing
- CHASSIS HARNESS REMOVAL
- Chassis Harness Installation
- SWITCHES / CONTROLS SERVICE
- Ignition Key Switch
- Transmission (Gear Position) Switch
- Seat Belt Switch
- Brake Pedal Switch Inspection
- ALL WHEEL DRIVE CIRCUIT SERVICE
- AWD / 2WD / TURF Switch
- Operation Overview
- Diagnosing System Failures
- VEHICLE SPEED SENSOR SERVICE
- Speed Sensor Location
- Speed Sensor Testing
- REAR DIFF SOLENOID SERVICE
- Differential Solenoid Overview
- Differential Solenoid Circuit Operation
- Differential Solenoid Replacement
- INSTRUMENT CLUSTER SERVICE
- Instrument Cluster Pinouts
- Instrument Cluster Service
- CHARGING SYSTEM SERVICE
- Stator
- Stator Inspection
- Stator Service
- Regulator / Rectifier Replacement
- Charging System Testing Flow Chart
- Charging System Troubleshooting
- Charging System Break Even Test
- Charging System Stator (Alternator) Tests
- Regulator Testing (900 Watt)
- BATTERY SERVICE
- Battery Specifications
- General Battery Information
- Battery Terminal Block
- Battery Off Season Storage
- Battery Identification
- Lead Acid Conventional Battery
- Lead Acid Conventional Battery Activation
- Lead Acid Conventional Battery Inspection
- Lead Acid Conventional Battery Charging and Testing
- Lead Acid Conventional Battery Maintenance
- Dry Shipped AGM Battery
- Dry Shipped AGM Battery Activation
- Dry Shipped AGM Battery Charging and Testing
- Dry Shipped AGM Battery Maintenance
- Lead Acid Low Maintenance Battery
- Lead Acid Low Maintenance Battery Charging and Testing
- Lead Acid Low Maintenance Battery Maintenance
- AGM Low Maintenance Battery
- AGM Low Maintenance Battery Charging
- AGM Battery Charging - Low Charge
- AGM Battery Charging - Deeply Discharged (Below 3 Volts)
- AGM Low Maintenance Battery Testing
- AGM Low Maintenance Battery Maintenance
- Battery Testing
- Battery Conductance Analyzer
- Battery Open Circuit Voltage Test (OCV)
- Battery Load Test
- Battery Specific Gravity Test
- Battery Charging Procedure
- ELECTRONIC POWER STEERING (EPS)
- EPS Operation
- LIGHTING SYSTEM SERVICE
- Headlamp Switch
- Headlight Adjustment
- Headlight Bulb Replacement
- Headlight Housing Service
- Tail Light Service