Polaris RANGER 1000 2020 User 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 2020 (PN 9850045 R01)
© Copyright 2020 Polaris 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.
2020-2021 RANGER 1000
Service Manual

SAFETY WARNINGS
The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved
when these words and symbols are used. Become familiar with their meanings before reading the manual.
DANGER
DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING
SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious
injury.
CAUTION
SAFETY ALERT CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor to moderate
injury.
NOTICE
NOTICE 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 11/06/2020 Initial release

FEEDBACK FORM
A feedback form has been created for the technician or consumer to provide Polaris
with an overall satisfaction rating for this service manual, provide comments on your
experience or upload pictures/video. This feedback form is viewable on a mobile
device by scanning the QR code or by clicking HERE if viewing this document
electronically.

2020-2021 RANGER 1000
Service Manual
Chapter Summary
CHAPTER 1 : GENERAL INFORMATION
CHAPTER 2 : MAINTENANCE
CHAPTER 3 : ENGINE / COOLING / EXHAUST
CHAPTER 4 : ENGINE ELECTRICAL
CHAPTER 5 : FUEL SYSTEM
CHAPTER 6 : PVT SYSTEM
CHAPTER 7 : TRANSMISSION
CHAPTER 8 : FINAL DRIVE
CHAPTER 9 : STEERING / SUSPENSION
CHAPTER 10 : BRAKE SYSTEM
CHAPTER 11 : BODY / FRAME
CHAPTER 12 : CHASSIS / BODY ELECTRICAL

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GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SERVICE RULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
SPECIAL TOOLS WEBSITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
SPECIAL TOOLS INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
MASTER TORQUE LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
VEHICLE AND ENGINE SERIAL NUMBER LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
MODEL SPECIFICATIONS - 3 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
MODEL SPECIFICATIONS - CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23
GENERAL DIAGNOSTICS INFORMATION OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.27
GUIDED SYMPTOM DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.27
GUIDED SYMPTOM REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28
ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.29
ENGINE CRANKS BUT DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.32
NO CRANK NO START OR SLOW CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.34
OVER HEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35
WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36
ENGINE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.37
COOLING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.39
DIGITAL WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40
DIGITAL WRENCH® SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40
GUIDED DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40
DIGITAL WRENCH® SOFTWARE INSTALLATION AND UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.41
DIGITAL WRENCH® COMMUNICATION ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.42
DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.42
DIGITAL WRENCH® SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.42
DIGITAL WRENCH® FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.43
ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.44
POLARIS MOBILE DIGITAL WRENCH® (PMDW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.45
ENGINE ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46
DIAGNOSTIC TROUBLE CODES OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46
MASTER TROUBLE CODE LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.47
CYLINDER MISFIRE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.58
FLUID LEAKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.59

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FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.59
FUEL SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.60
FUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.60
PVT SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.62
PVT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.62
PVT SYSTEM OVERHEATING / DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.64
TRANSMISSION DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65
TRANSMISSION ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65
FINAL DRIVE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66
ALL WHEEL DRIVE (AWD) CONCERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66
DRIVESHAFT (HALF SHAFT) DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66
BRAKE SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.67
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.67
BRAKE VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.67
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.68
POOR BRAKE PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.68
BRAKES LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.68
STEERING / SUSPENSION DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.69
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) . . . . . . . . . . . . . . . . . . . . . .1.69
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) . . . . . . . . . . . . . . . . . . . . .1.70
EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.71
SHOCK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.72
ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73
DIGITAL MULTI-METER (DMM) NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73
STATIC AND DYNAMIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73
CONNECTOR PROBING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.74
TESTING CONTINUITY / RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75
TESTING FOR A SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75
TESTING FOR A SHORT TO VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.76
TESTING FOR INTERMITTENT CONDITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.77
TESTING CURRENT FLOW (AMPERAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.77
CURRENT DRAW - KEY OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.78
TESTING VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.78
GENERAL INFORMATION

9850045 R01 - 2020-2021 RANGER 1000 Service Manual
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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. Notice, 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
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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.polaris.com).
NOTICE
When ordering service parts be sure to use the correct parts manual.
MODEL MODEL NUMBER OWNER’S MANUAL
2020 RANGER 1000
R20TAA99A1 / A7
R20TAA99B1 / B7
R20TAE99A1 / A7 / A9 / AM / AS / AZ
R20TAE99B1 / B7 / B9 / BM / BS / BZ
9930790
2020 RANGER 1000 Factory Choice R20TAU99AM / AS / AZ
R20TAU99BM / BS / BZ
2020 RANGER 1000 CREW
R20T6A99A1
R20T6A99B1
R20T6E99A9 / AM / AS
R20T6E99B9 / BM / BS
2020 RANGER 1000 CREW Factory Choice R20T6U99AM / AS
R20T6U99BM / BS
2021 RANGER 1000
R21TAA99A1 / A7
R21TAA99B1 / B7
R21TAE99A1 / A7 / A9 / AG / AP / AS
R21TAE99B1 / B7 / B9 / BG / BP / BS
R21TAE99FA / JA
9939983
2021 RANGER 1000 Factory Choice R21TAU99AG / AP
R21TAU99BG / BP
2021 RANGER 1000 CREW
R21T6A99A1
R21T6A99B1
R21T6E99A9 / AG / AP
R21T6E99B9 / BG / BP
2021 RANGER 1000 CREW Factory Choice R21T6U99AG / AP
R21T6U99BG / BP
2021 RANGER 1000 EU (Intl.) R21TAE99FA
9931406
2021 RANGER 1000 ZUG (Intl.) R21TAS99FA
2021 RANGER 1000 Israel (Intl.) R21TAE99JA
9931407
2021 RANGER 1000 Tractor (Intl.) R21TAS99CA / CK
GENERAL INFORMATION

9850045 R01 - 2020-2021 RANGER 1000 Service Manual
© Copyright Polaris Inc. 1.5
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
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1.6 9850045 R01 - 2020-2021 RANGER 1000 Service Manual
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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

9850045 R01 - 2020-2021 RANGER 1000 Service Manual
© Copyright Polaris Inc. 1.7
SPECIAL TOOLS INDEX
MAINTENANCE
TOOL
DESCRIPTION PART NUMBER IMAGE
Oil Filter
Wrench PU-50105
Shock Spanner
Wrench 2877408
ENGINE
TOOL
DESCRIPTION PART NUMBER IMAGE
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
TOOL
DESCRIPTION PART NUMBER IMAGE
Engine Stand
Sleeve Adapter
(Use With 2”
Bore Stand)
PU-50625
Engine Stand
Sleeve Adapter
(Use With
2.375” Bore
Stand)
PW-47054
Water Pump
Mechanical Seal
Installer
PU-50564
Valve Spring
Compressor
Adapter
PU-52917
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
GENERAL INFORMATION
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1.8 9850045 R01 - 2020-2021 RANGER 1000 Service Manual
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TOOL
DESCRIPTION PART NUMBER IMAGE
Crank Seal
Installation Tool PU-52493
Clutch Center
Distance Tool PU-50658
FUEL SYSTEM
TOOL
DESCRIPTION PART NUMBER IMAGE
Fuel Pressure
Gauge Kit PU-43506-A
Fuel Pressure
Gauge Adapter PA-48838
Fuel Pressure
Gauge Adapter PS-48762
Fuel Pump
Service Tool PU-50326
PVT SYSTEM
TOOL
DESCRIPTION PART NUMBER IMAGE
Drive Clutch
Holding Tool PU-52430
Drive Clutch
Puller PU-52422
Clutch
Compressor
Tool
PU-50518–A
Clutch Bushing
Replacement Kit 2871226–A
Piston Pin Puller 2870386
Roller Pin Tool 2870910
Driven Clutch
Separator Tool 2883577
GENERAL INFORMATION

9850045 R01 - 2020-2021 RANGER 1000 Service Manual
© Copyright Polaris Inc. 1.9
TRANSMISSION
TOOL
DESCRIPTION PART NUMBER IMAGE
Snorkel Tool PU-52547
Rear Driveshaft
Seal Guide 2871699
Rear Output
Seal Driver 2871698
Bearing Seal
Driver (50 mm) 2871282
FINAL DRIVE
TOOL
DESCRIPTION PART NUMBER IMAGE
Roll Pin
Removal Tool 2872608
Axle Boot
Clamp Tool PU-48951
CV Boot Clamp
Pliers 8700226
BRAKE SYSTEM
TOOL
DESCRIPTION PART NUMBER IMAGE
Mityvac®
Pressure Test
Tool
2870975
BODY / FRAME
TOOL
DESCRIPTION PART NUMBER IMAGE
Multi-Function
Pliers 2876389
ELECTRICAL
TOOL
DESCRIPTION PART NUMBER IMAGE
Digital Wrench®
Diagnostic Kit PU-47063-B
Digital Wrench®
Vehicle Interface
Cable
PU-47469
Digital Wrench®
PC Interface
Cable
PU-47470
Digital Wrench®
SmartLink
Module
PU-47468
Digital Wrench®
SmartLink Kit PU-47471
MultiLink XP
Module PU-52789
Vehicle Interface
Harness PU-52790
MultiLink XP
USB Cable PU-52791
GENERAL INFORMATION
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1.10 9850045 R01 - 2020-2021 RANGER 1000 Service Manual
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TOOL
DESCRIPTION PART NUMBER IMAGE
Wireless Vehicle
Link (WVL) PU-51435
Fluke™ 77
Digital
Multimeter
PV-43568
Static Timing
Light Harness 2871745
Hall Effect
Sensor Probe
Harness
2460761
Battery
Conductance
Analyzer (MDX-
610P)
PU-50296
Connector Test
Kit PV-43526
Timing Light 2870630
Relay Bypass PU-49466
GENERAL INFORMATION

9850045 R01 - 2020-2021 RANGER 1000 Service Manual
© Copyright Polaris Inc. 1.11
MASTER TORQUE LIST
MAINTENANCE
PART DESCRIPTION TORQUE SPECIFICATION
Battery Hold Down Bracket
Fastener
6 ft-lbs (8 Nm)
Battery Terminal Fastener 40 in-lbs (5 Nm)
Caliper Bleeder Screw 4 ft-lbs (5.4 Nm)
Coolant Hose Clamp 35 in-lbs (4 Nm)
Crankcase Drain Plug 12 ft-lbs (16 Nm)
Front Gearcase Fill / Drain
Plug
10 ft-lbs (14 Nm)
Outer Clutch Cover Fastener 35 in-lbs (4 Nm)
Shock Mounting Fastener 40 ft-lbs (54 Nm)
Spark Arrestor Fastener 7 ft-lbs (10 Nm)
Spark Plug 15 ft-lbs (20 Nm)
Tensioner Mounting
Fastener
7 ft-lbs (10 Nm)
Tie Rod Jam Nut 13 ft-lbs (18 Nm)
Timing Chain Tensioner
Plunger Fastener
15 ft-lbs (20 Nm)
Transmission Fill / Drain
Plug
12 ft-lbs (16 Nm)
Valve Cover Fastener 7 ft-lbs (10 Nm)
Wheel Hub Castle Nut (front) 80 ft-lbs (108 Nm)
Wheel Hub Castle Nut (rear) 110 ft-lbs (149 Nm)
Wheel Lug Nuts (Aluminum) 120 ft-lbs (163 Nm)
Wheel Lug Nuts (Steel) 60 ft-lbs (81 Nm)
ENGINE / COOLING / EXHAUST
PART DESCRIPTION TORQUE SPECIFICATION
Air Duct Clamps 35 in-lbs (4 Nm)
Airbox Mount Fastener 44 in-lbs (5 Nm)
Cam Chain Tensioner 15 ft-lbs (20 Nm)
Camshaft Carrier Fastener 7 ft-lb (10 Nm)
Camshaft Sprocket Fastener 14 ft-lbs (19 Nm)
Case Plug 22 ft-lbs (30 Nm)
Connecting Rod Fastener Step 1: 9 ft-lbs (12 Nm)
Step 2: 22 ft-lbs (30
Nm)
Step 3: Tighten
additional 90°
Coolant Bleed Fastener 6 ft-lbs (8 Nm)
Coolant Hose Clamp 35 in-lbs (4 Nm)
Coolant Hose Mounting
Bracket Fastener (M6 Bolt) 44 in-lbs (5.0 Nm)
Coolant Hose Mounting
Bracket Fastener (Screw) 22 in lbs (4.5 Nm)
Coolant Reservoir Fasteners 24 in-lbs (3 Nm)
Cooling Fan Fasteners 35 in-lbs (4 Nm)
Cooling Fan Shroud
Fasteners 6 ft-lbs (8 ft-lbs)
Crankcase Drain Plug 12 ft-lbs (16 Nm)
Crankcase Oil Gallery Plug 22 ft-lbs (30 Nm)
Cylinder Head Fastener
(M11 Bolts) Torque in sequence
Step 1: 13 ft-lbs (18
Nm)
Step 2: 26 ft-lb (35 Nm)
Step 3: Tighten
additional 360°
Cylinder Head Fastener (M6
Bolts) 7 ft-lb (10 Nm)
Engine Mount Fastener
(M10) 40 ft-lbs (54 Nm)
Engine Mount Isolator Nuts
(M8) 22 ft-lbs (30 Nm)
Exhaust Head Pipe
Mounting Fastener 22 ft-lbs (30 Nm)
Exhaust Stud w/Spring 21 ft-lbs (28 Nm)
GENERAL INFORMATION
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1.12 9850045 R01 - 2020-2021 RANGER 1000 Service Manual
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PART DESCRIPTION TORQUE SPECIFICATION
Flywheel Retaining Fastener Step 1: Torque to 129
ft-lbs (175 Nm)
Step 2: Back out bolt
180°
Step 3: Torque to 129
ft-lbs (175 Nm)
Heater Valve Fasteners 6 ft-lbs (8 Nm)
Heat Shield Fastener
(Exhaust Pipe) 6 ft-lbs (8 Nm)
Heat Shield Fastener (Body) 42 in-lbs (5 Nm)
Intake Duct Hose Clamp 35 in-lbs (4 Nm)
Intake Manifold Adapter 7 ft-lbs (10 Nm)
Intake Manifold Boot Clamp 17 in-lbs (2 Nm)
Lower Crankcase Fastener
(M10) Step 1: 9 ft-lb (12 Nm)
Step 2: 21 ft-lb (28 Nm)
Step 3: Tighten
additional 90°
Lower Crankcase Fastener
(M6) 9 ft-lbs (12 Nm)
Lower Crankcase Fastener
(M8) 26 ft-lbs (35 Nm)
Lower Intake Plenum
Fastener 18 ft-lbs (24 Nm)
Muffler Mount Fastener 10 ft-lbs (14 Nm)
Oil Filter Adapter 21 ft-lbs (28 Nm)
Oil Cooler Retaining
Fastener 7 lb-ft (10 Nm)
Oil Pump Mounting Fastener 7 ft-lbs (10 Nm)
Oil Pump Pick-Up Retaining
Fastener 7 ft-lbs (10 Nm)
Oil Pump Sprocket Fastener 7 ft-lbs (10 Nm)
Oil Sump Cover Fastener
(M6) 9 ft-lbs (12 Nm)
Oil Sump Cover Fastener
(M8) 26 ft-lbs (35 Nm)
One Way Clutch Retaining
Fastener 9 ft-lbs (12 Nm)
Rear Engine Mount
Fasteners 45 ft-lbs (61 Nm)
Rear Engine Mount
Fasteners (Preliminary
Torque)
5 ft-lbs (7 Nm)
PART DESCRIPTION TORQUE SPECIFICATION
Stator Cover Fastener 9 ft-lbs (12 Nm)
Tensioner Mounting
Fastener
7 ft-lbs (10 Nm)
Thermostat Cover Fastener 7 ft-lbs (10 Nm)
Throttle Body Fasteners 7 ft-lbs (10 Nm)
Upper Crankcase Fastener
(M6) 7 ft-lbs (10 Nm)
Upper Crankcase Fastener
(M8) 26 ft-lbs (35 Nm)
Valve Cover Fastener 7 ft-lbs (10 Nm)
Water Pump Impeller
Fastener
7 ft-lbs (10 Nm)
(Apply Loctite®204™ to
bolt threads)
Water Pump Mounting
Fastener 7 ft-lbs (10 Nm)
GENERAL INFORMATION