What kind of problems does a Polaris Ranger Crew normally have? In this blog, we’ve outlined all the most important things you should watch for when you’re in the market for a Polaris Ranger Crew. In the rest of the article, we’ll discuss every single problem in detail. Furthermore, we’ll tell you how to identify it, fix it and how much it costs to fix. Read on!

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Polaris Ranger Crew Problems

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1. Drive Belt Issues

Continuously variable transmission (CVT) drive belt failure is a typical UTV problem. Most belt issues are preventable, but some of them are costly to resolve. Heat is one of the drive belt’s worst adversaries. So, the problems often stem from inadequate maintenance, poor riding style, extreme use, and abuse. For example, the belt will burn if you drive slowly in a high range with a heavy load, drive with the brakes on, or speed.

Also, while the wheels are stuck, applying the throttle causes the drive clutch to rotate except the belt. It burns the belt in one spot, shortening its lifespan. For example, a customer says,

“My friend in high gear in the mud in my Crew, and kept hammering the gas. After that, the transmission started to feel jerky and slip, and a terrible clunking sound appeared to come from the transmission. When I got home, I removed the belt, and sure enough, there was an “hourglass” form in one spot on the underside of the belt.”

The performance and lifespan of the belt can suffer if water, mud, or debris enter the CVT case, particularly the clutches’ sheave. Additionally, the belt’s performance and life are affected by its tightness or looseness. Using the low gear drive range when traveling at a low speed is the easiest method for extending the belt lifespan.

The belt experiences less strain, and the moving parts receive more cooling air. It keeps them cool and prolongs their life. Verify that the belt deflection complies with the manufacturer’s specifications. Moreover, avoid covering or obstructing the factory vents. OEM Polaris Ranger Crew drive belt replacement costs $159.99.

2. Battery Problems

Many customers find that the stock battery doesn’t last long. The stock battery may still show 12v+ after charging, but that is not a genuine reflection of its actual condition. The Voltage Regulator cannot charge a defective battery or a good battery with faulty connections. Most auto parts shops will load-test your battery for free. Bench charge the battery before taking it in for testing.

For example, a customer asks,

“The battery on my crew isn’t recharging. Has anyone else experienced this issue with theirs?”

Weak batteries increase the load on charging systems and cause an early system failure. These vehicles’ charging systems don’t produce a lot of amperage at low engine speeds. So, the system may be unable to keep up with demand if it makes frequent short trips at low speeds, especially if you have accessories that consume a lot of amperage. Upgrade your battery.

Also read: 10 x Most Common Polaris Ranger XP 1000 Problems!

3. Worn Out Fuel Pump 

After a few years or a few thousand miles, the fuel pump begins to wear out, and the pressure it delivers to the fuel injectors drops below 30 psi. A faulty fuel pump may result in a difficult start, sputters, backfiring, power loss, or even an unexpected engine shutdown while moving. Typical signs of this issue include Low RPM, slow acceleration, and a reduced top speed.

Your engine will run lean if it doesn’t receive enough fuel. This causes heat to build up in the combustion chamber, which could lead to detonation. The intense heat can even melt a hole in your piston. Install a fuel pressure gauge at the fuel tank outlet, then use it to check the fuel pump pressure during routine operation. Replace the fuel pump if the psi is in the lower 30s. OEM Polaris Ranger Crew replacement fuel pump costs $79.99.

Also read: 5 x Most Common Polaris Fuel Pump Problems!

4. Steering Issues  

The EPS system turns off automatically when your UTV starts and idles for two to three minutes. This function prevents the EPS from depleting your batter while you are not using it. Often, this Polaris function causes alarm among many owners, who mistake it for an EPS failure. Simply restarting your Crew will turn the power steering back on.

The EPS should turn on immediately after switching it off and back on. The EPS will get disconnected if you simultaneously apply the brake and the gas. When driving over rocks or across other hazardous terrains, some drivers place one foot on the brakes and the other on the accelerator. When you restart the UTV, the EPS should appear immediately.

Besides this, if a fuse in the EPS blows, you would see the same system. So, examine the fuses if restarting doesn’t bring your EPS online. For example, a customer says,

“My 21 Crew has a new problem; I took it to the dealer for the first service, and the moment I unpacked it at home, I noticed the steering wheel was harder to move. It led me to believe the power steering was not functioning.
I called the store, and the service manager reassured me everything was ok. Just wondering if anyone else has experienced this problem and the solution.”

Also read: 6 x Most Common Polaris Steering Problems!

5. Shifting problems

Many customers have reported their Ranger Crews being unable to shift the gear properly after a while. For example, a customer reports,

“My 2020 has been having problems shifting into neutral since a few months ago. Started as soon as I stopped, I placed it in low, and it took a little while to engage, but when it did, the entire machine shook.
After that, whenever I stopped, like at a stop sign, it would switch to neutral. I have to shift it to neutral and then back to high before it can move. What could be the problem?”

Diverse factors, such as faulty cables, filthy clutches, a weak clutch spring, worn or torn drive belts, or worn EBS washers, might result in gear shift issues. The problems could also arise from an aftermarket drive belt, a defective engine mount, misaligned clutches caused by an offset belt, and faulty or worn-out one-way bearing. An OEM Polaris ranger crew shift cable is around $69.95.

6. Clutch problems

The vehicles may experience primary clutch failure under certain circumstances. Often, this happens in high-load, low-speed situations, such as high-boost vehicle launches, high-RPM belt slips, and launches with the brake and throttle applied simultaneously. The second clutch issue you can encounter is a high drag, which makes changing gears difficult.

These clutch issues could be brought on by the clutch steel rollers’ metal bushing failing. The older models had better fiber bushing. The new Polaris clutch kit features a talon fiber bushing for improved performance. The engine braking system (EBS) can also contribute to the clutch problem. The one-way bearing may lock up or tighten, causing drag and hard shifting.

If your machine is idle for an extended period, the rollers in the kit also frequently fail. The EBS lockout shim for primary clutches and the plastic one-way bearing helix can become ineffective due to accumulated debris and dust. The updated Polaris EBS assembly and special stainless-steel shims can fix these issues. The EBS helix lockout shim for the primary clutch costs $20.00.

Also read: 5 x Most Common Polaris Clutch Problems!

7. Engine Challenges

You can try a few straightforward troubleshooting techniques to figure out the engine issue

If the engine is idling but not revving:

Check whether an excessive gas flow is causing the engine to flood. Check the fuel pump, line, valve, filter, and tank vent. Ensure the tank is full. Check the spark plug and the starter circuit in the ignition system. Examine the cylinder for high leakage.

When the engine won’t crank:

Check the battery, solenoid, starter motor, and other starter parts. Also, rust, a mechanical issue, or a seized engine could be to blame.

When the engine starts but does not rev:

Clean or replace the air filter and other air intake components. Furthermore, inspect the throttle cable, TRS switch, spark plug, and ignition timing. Examine the exhaust system and reverse speed limiter.

If the engine starts but won’t idle:

Clean the air filter and examine the fuel system and crankcase breather. Ensure that the choke and fuel system are well-adjusted. Examine the cylinder for high leakage. OEM Polaris Ranger Crew engine head gasket costs about $54.99.

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