Polaris Sportsman XP Touring 1000 User manual

2018
OWNER’S MANUAL
RANGER® 1000 Diesel
RANGER® 1000 Diesel EPS
RANGER CREW® 1000 Diesel

WARNING
Read, understand, and follow all of the instructions
and safety precautions in this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR
code with your smartphone.

1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of
POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new
product introductions, upcoming events, career opportunities and more.
We believe POLARIS sets a standard of excellence for all utility and recreational vehicles
manufactured in the world today. Many years of experience have gone into the engineering,
design, and development of your POLARIS vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the instructions and
recommendations in this owner’s manual.
Your manual contains instructions for minor maintenance, but information about major
repairs is outlined in the POLARIS Service Manual and can be performed by a factory
certified Master Service Dealer® (MSD) Technician.
Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction.
Your POLARIS dealership can provide for all of your service needs during, and after, the
warranty period.
• Snowmobiles • RZR®sport vehicles
• All-terrain vehicles (ATVs) • GEM® electric vehicles
• Low emission vehicles (LEVs) • VICTORY® motorcycles
•RANGER®utility vehicles • INDIAN® motorcycles
•BRUTUS®work vehicles • POLARIS POWER® generators
• SLINGSHOT® three wheel motorcycles • POLARIS DEFENSE® combat vehicles

2
POLARIS®, RANGER® and RANGER CREW® are trademarks of POLARIS Industries Inc.
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.
The original instructions for this vehicle are in English. Other languages are provided as translations of the
original instructions.
Printed in U.S.A.
2018 RANGER Diesel / RANGER CREW Diesel Owner’s Manual
P/N 9928298

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Features and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
POLARIS Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

4
INTRODUCTION
The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations
concerning the operation of this vehicle in your area.
The following signal words and symbols appear throughout this manual and on your vehicle.
Your safety is involved when these words and symbols are used. Become familiar with their
meanings before reading the manual.
The safety alert symbol indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate
injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

5
INTRODUCTION
Failure to follow the warnings contained in this manual can result in severe injury or death.
Your POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently
than other vehicles, such as cars, trucks or other off-road vehicles. A collision or rollover can occur
quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.
• Read this owner’s manual and review the safety DVD that came with your vehicle. A free extra copy
of the DVD can be obtained by contacting your local POLARIS dealer. Understand all safety
warnings, precautions and operating procedures before operating the vehicle. Keep this manual with
the vehicle.
• Review the safety DVD and take the free online Recreational Off-Highway Vehicle Association
(ROHVA) training course at www.rohva.org.
• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and have a valid driver’s
license to operate this vehicle.
• No person under the age of 12 may ride as a passenger in this vehicle. All riders must be able to sit
with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if
driving) or on a passenger hand hold.
• Never permit a guest to operate this vehicle unless the guest has read this manual and all product
labels.
• Always use the cab nets (or doors) while riding in this vehicle. Always keep hands, feet and all other
body parts inside the vehicle at all times.
• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle
boots.
• Never use this vehicle with drugs or alcohol, as these conditions impair judgment and reduce
operator reaction time.
WARNING

6
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the spaces provided.
Remove the spare key and store it in a safe place. An ignition key can be duplicated only by
ordering a POLARIS key blank (using your key number) and mating it with one of your
existing keys. The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ________________________________________________________________________
Frame VIN: _________________________________________________________________________________
Engine Serial Number: ________________________________________________________________________
Key Number: ________________________________________________________________________________
Engine Serial Number
VIN
Key Number
####

7
INTRODUCTION
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration levels of this machinery
is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as indicated by the
test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature

8
SAFETY
Safe Riding Gear
The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt,
long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance
of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle,
always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT)
label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05
label. The ECE mark consists of a circle surrounding the letter E,
followed by the distinguishing number of the country which has granted
approval. The approval number and serial number will also be displayed
on the label.
E
4
051039
0006.31
Helmet
Eye Protection
Gloves
Over-the-Ankle
Boots
Long Pants
Long
Sleeves

9
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this
POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face
shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE)
bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept
clean.
Gloves
Wear gloves for comfort and for protection from sun, cold weather and other elements.
Boots
Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle
with bare feet or sandals.
Clothing
Wear long sleeves and long pants to protect arms and legs.
Rider Comfort
Under certain operating conditions, heat generated by the engine and exhaust system can
elevate temperatures in the driver and passenger cab area. The condition occurs most
frequently when a vehicle is being operated in high ambient temperatures at low speeds and/
or high load conditions for an extended period of time. The use of certain windshield, roof
and/or cab systems may contribute to this condition by restricting airflow. Any discomfort
due to heat buildup in this area can be minimized by wearing proper riding apparel and by
varying speeds to increase airflow.

10
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection. Read and follow the
instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual
differ from the labels on your vehicle, always read and follow the instructions of the labels
on the vehicle.
If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a
replacement. Replacement safety labels are provided by POLARIS at no charge. The part
number is printed on the label.
Proper Use Warning (Diesel)
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
• Do not allow careless or reckless driving.
• Make sure operators are 16 or older with a valid driver’s license.
• Do not let people drive or ride after using alcohol or drugs.
• Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions
with cars and trucks can occur.
• Do not exceed seating capacity: 3 occupants. 7179979
Proper Use Warning (CREW Diesel)
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
• Do not allow careless or reckless driving.
• Make sure operators are 16 or older with a valid driver’s license.
• Do not let people drive or ride after using alcohol or drugs.
• Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions
with cars and trucks can occur.
• Do not exceed seating capacity: 6 occupants. 7179981
Proper Use
Warning Payload Warning
Shift Caution
Seat Belt/Drive
Responsibly
Warning

11
SAFETY
Safety Labels and Locations
Fuel Transport Warning
This label can be found in the rear cargo box.
WARNING
NEVER carry fuel or other flammable liquids on this vehicle. Failure to
follow this instruction could lead to serious burn injuries or death. 7186122
Payload Warning/Shift Caution
WARNING
CAUTION
To avoid transmission damage, shift only when vehicle is stationary and at idle. When vehicle is
stopped, place shift in parked position. 7181599
Seat Belt/Drive Responsibly Warning
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH
Be Prepared
• Fasten seat belts.
• Wear an approved helmet and protective gear.
• ALWAYS use cab nets and/or doors.
• Each rider must be able to sit with back against seat, feet flat on the floor,
and hands on steering wheel or hand holds. Stay completely inside the
vehicle.
Drive Responsibly
Avoid loss of control and rollovers:
• Avoid abrupt maneuvers, sideways sliding, skidding or fishtailing,
and never do donuts.
• Slow down before entering a turn.
• Avoid hard acceleration when turning, even from a stop.
• Plan for hills, rough terrain, ruts and other changes in traction and
terrain. Avoid paved surfaces.
• Avoid sidehilling (riding across slopes).
Be Sure Riders Pay Attention and Plan Ahead
If you think or feel the vehicle may tip or roll, reduce your risk of injury:
• Keep a firm grip on the steering wheel or hand holds and brace yourself.
• Do not put any part of your body outside of the vehicle for any reason.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING (rohva.org). 7185094
RANGER Never Exceed If Total Payload Exceeds
Diesel 20 MPH (32.2 Km/h) 1080 lbs. (490 kg)
CREW Diesel 35 MPH (56.3 Km/h) 1490 lbs. (676 Kg)
Rollovers have caused
severe injuries and death,
even on flat, open areas.

12
SAFETY
Safety Labels and Locations
Load/Passenger/Tire Pressure Warning
WARNING
• Never carry passengers in cargo box.
• Passengers can be thrown off. This can cause
serious injury or death.
• If total payload is greater than 500 lbs., the
vehicle must be operated in LOW range.
IMPROPER TIRE PRESSURE OR
OVERLOADING CAN CAUSE LOSS OF
CONTROL RESULTING IN SERIOUS INJURY
OR DEATH.
• Reduce speed and allow greater distance for
braking when carrying cargo.
• Overloading or carrying tall, off-center, or
unsecured loads will increase your risk of losing control. Loads should be centered and carried as
low as possible in box.
• For stability on rough or hilly terrain, reduce speed and cargo.
7185781
Clutch Cover Warning
WARNING
Improper service or maintenance of this PVT system can result
in vehicle damage, SEVERE INJURY or DEATH.
Always look for and remove debris inside and around clutch
and vent system when replacing belt.
Read owner’s manual or see authorized POLARIS dealer.
7177469
RANGER Diesel 4x4 4x4 CA CREW CA CREW
MAXIMUM CARGO BOX LOAD 1000 lbs.
(454 kg) 600 lbs. (272 kg) 1000 lbs. (454 kg) 600 lbs. (272 kg)
TIRE PRESSURE IN PSI (KPa) FRONT 10 (69)
REAR 12 (83) FRONT 10 (69) REAR 12 (83) FRONT 14 (96) REAR 16 (110) FRONT 14 (96) REAR 16 (110)
MAXIMUM WEIGHT CAPACITY
INCLUDES WEIGHT OF
OPERATOR, PASSENGER,
CARGO AND ACCESSORIES
1500 lbs.
(682 kg) 1100 lbs. (499 kg) 1750 lbs. (795 kg) 1350 lbs. (612 kg)
Read Operation and Maintenance Manual for more detailed loading information.
X
Clutch Cover
Warning

13
SAFETY
Operator Safety
Serious injury or death can result if you do not follow these instructions and procedures, which are
outlined in further detail within your owner's manual.
• Read this entire manual and all labels carefully. Follow the operating procedures
described.
• Never allow anyone under the age of 16 to operate this vehicle and never allow anyone
without a valid driver's license to operate this vehicle.
• Do not carry a passenger until you have at least two hours of driving experience with this
vehicle.
• No person under the age of 12 may ride as a passenger in this vehicle. All riders must be
able to sit with backs against the seat, both feet flat on the floor and both hands on the
steering wheel (if driving) or on a passenger hand hold.
• The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt,
long pants, over-the-ankle boots and seat belt at all times.
• Always use the cab nets (or doors) while riding in this vehicle.
• Always keep hands and feet inside the vehicle at all times.
• Always keep both hands on the steering wheel and both feet on the floorboards of the
vehicle during operation.
• Never permit a guest to operate this vehicle unless the guest has read this manual and all
product labels.
• To reduce rollover risk, be especially careful when encountering obstacles and slopes and
when braking on hills or during turns.
• This vehicle is for off road use only. Never operate on public roads (unless marked for off-
road use). Always avoid paved surfaces.
• Never consume alcohol or drugs before or while operating this vehicle.
• Never operate at excessive speeds. Always travel at a speed proper for the terrain,
visibility and operating conditions, and your experience.
• Never attempt jumps or other stunts.
• Always inspect the vehicle before each use to make sure it's in safe operating condition.
Always follow the inspection procedures described in this manual.
WARNING

14
SAFETY
Operator Safety
• Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert
to changing terrain.
• Never operate on excessively rough, slippery or loose terrain.
• Always follow proper procedures for turning. Practice turning at slow speeds before
attempting to turn at faster speeds. Never turn at excessive speeds.
• Always have this vehicle checked by an authorized POLARIS dealer if it has been
involved in an accident.
• Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice
on smaller hills before attempting larger hills.
• Always follow proper procedures for climbing hills as described in this manual. See page
47. Check the terrain carefully before attempting to climb a hill. Never climb hills with
excessively slippery or loose surfaces. Never apply throttle suddenly. Never make sudden
gear changes. Never go over the top of a hill at high speed.
• Always follow the proper procedures outlined in this manual for traveling downhill and
for braking on hills. See page 47. Check the terrain carefully before descending a hill.
Never travel downhill at high speed. Avoid going downhill at an angle, which would cause
the vehicle to lean sharply to one side. Travel straight down the hill where possible.
• Always check for obstacles before operating in a new area. Never attempt to operate over
large obstacles such as large rocks or fallen trees. Always follow the proper procedures
outlined in this manual when operating over obstacles. See page 45.
• Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowly
and exercise caution to reduce the chance of skidding or sliding out of control.
• Never operate your vehicle in fast-flowing water or in water deeper than that specified in
this manual. See page 48. Wet brakes may have reduced stopping ability. Test your brakes
after leaving water. If necessary, apply them lightly several times to let friction dry out the
pads.
• Always be sure there are no obstacles or people behind your vehicle when operating in
reverse. When it's safe to proceed in reverse, move slowly. Avoid turning at sharp angles
in reverse.

15
SAFETY
Operator Safety
• Always use the proper size and type of tires specified in this manual. Always maintain
proper tire pressure as specified on safety labels.
• Never modify this vehicle through improper installation or use of non-POLARIS
approved accessories.
• Never exceed the stated load capacity for this vehicle. Cargo should be properly
distributed and securely attached. Reduce speed and follow the instructions in this manual
for hauling cargo or pulling a trailer. Allow a greater distance for braking.
• Always place the transmission in PARK before getting out of the vehicle.
• Always stop the engine before refueling. Remove flammable material containers from the
box before filling them with fuel. Make sure the refueling area is well ventilated and free
of any source of flame or sparks.
• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use
by someone under the age of 16 or without a driver’s license and proper training, or
accidental starting.
FOR MORE INFORMATION ABOUT SAFETY,
call POLARIS at 1-800-342-3764.
Equipment Modifications
Do not install any non-POLARIS approved accessory or modify the vehicle for the purpose
of increasing speed or power. Any modifications or installation of non-POLARIS approved
accessories could create a substantial safety hazard and increase the risk of bodily injury.
The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non-
POLARIS approved equipment and/or modifications have been added to the vehicle that
increase speed or power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires,
sprayers, or large racks, may change the handling characteristics of the vehicle. Use only
POLARIS-approved accessories, and familiarize yourself with their function and effect on
the vehicle.

16
SAFETY
Operator Safety
Failure to operate the RANGER properly can result in a collision, loss of control, accident or rollover,
which may result in serious injury or death. Heed all safety warnings outlined in this section of the
owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if
you are under age 16 and NEVER operate without a valid driver’s
license.
Never operate with a passenger under the age of 12. All riders must be
able to sit with backs against the seat, both feet flat on the floor and both
hands on the steering wheel (if driving) or on a passenger hand hold.
Operating Without Instruction
Operating this vehicle without proper instruction increases the risk of an
accident. The operator must understand how to operate the vehicle
properly in different situations and on different types of terrain.
All operators must read and understand the Owner's Manual and all
warning and instruction labels before operating the vehicle.
All operators should review the safety DVD provided with this vehicle and
take a ROHVA training course (www.rohva.org).
Using Alcohol or Drugs
Operating the vehicle after consuming alcohol or drugs could adversely
affect operator judgment, reaction time, balance and perception.
Never drink alcohol or use drugs or medications before or while
operating this vehicle.
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of
serious injury in the event of rollover, loss of control, other accident or
sudden stop. Seat belts may reduce the severity of injury in these
circumstances.
All riders must wear seat belts at all times.
Protective Apparel
Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of
a serious injuries in the event of an accident.
Operator and all passengers must always wear an approved helmet that fits properly and eye
protection (goggles or face shield).
WARNING

17
SAFETY
Operator Safety
Cab Nets
Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious
injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in
this vehicle.
Always keep hands and feet inside the vehicle at all times.
Failure to Inspect Before Operating
Failure to inspect and verify that the vehicle is in safe operating condition before operating increases
the risk of an accident. Always perform the pre-ride inspection before each use of your RANGER to
make sure it's in safe operating condition. See page 36.
Always follow all inspection and maintenance procedures and schedules described in this owner's
manual. See page 65.
Operating With a Load on the Vehicle
The weight of both cargo and passengers impacts vehicle operation. For your safety and the safety of
others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the
instructions in this manual for loading, tire pressure, gear selection and speed.
•Do not exceed vehicle weight capacities. The vehicle’s maximum weight capacity is listed in the
specifications section of this manual and on a label on the vehicle. When more passenger weight is
added, cargo weight may need to be reduced accordingly.
• The recommended tire pressures are listed in the specifications section of this manual and on a label
on the vehicle.
Always follow these guidelines:
Under ANY of these conditions: Do ALL of these steps:
Passenger and/or cargo exceeds half the maximum weight capacity 1. Slow down.
2. Verify tire pressure.
3. Use extra caution when
operating.
Operating in rough terrain
Operating over obstacles
Climbing an incline
Towing

18
SAFETY
Operator Safety
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time.
Never start the engine or let it run in an enclosed area.
The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other
reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle. Hot components can
cause burns and fire. Do not touch hot exhaust system components or brake system components.
Always keep combustible materials away from the exhaust system. Use caution when traveling through
tall grass, especially dry grass, to avoid debris build-up around the exhaust system.
Improper Tire Maintenance
Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of
control or accident. Always use the size and type of tires specified for your vehicle. Always maintain
proper tire pressure as described in the owner's manual and on safety labels.
Unauthorized Use of the Vehicle
Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age
of 16, without a drivers license, or without proper training. This could result in an accident or rollover.
Always remove the ignition key when the vehicle is not in use.