Polaris Ranger 900 XP, Installation Instructions Manual

Page 1: ...INSTALLATION INSTRUCTIONS POLARIS RANGER 900 XP...

Page 2: ...product dealer do the install for you Some parts contain sharp edges wear protective gloves if necessary Always keep your assembly area clean uncluttered and well lit Keep visitors and children a safe...

Page 3: ...detergents that could scratch the surface plates abrasives harsh fabrics etc Do not use solvents or alkaline detergents or cleaners with ammonia ammonium hydroxide Do not remove the impurities from th...

Page 4: ...MERICA INC 630 324 8585 4 TOOLS NEEDED Not included Ratchet handle Socket beg 17 mm Socket beg 13 mm 0 67 in 0 51 in For tightening straps Socket beg 8 mm Metric wrench 13mm Utility knife 0 31 in 17mm...

Page 5: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 5 Drill 2 5 4mm Drill 8mm Drill 12 mm 0 1 0 16 in 0 31 0 33 in 0 5 in Drill 21mm 0 83 in...

Page 6: ...INSTALLATION Uninstall all additional systems from the roller cages work lights rear mirrors drink holders etc ELECTROINSTALLATION WIPER WASHER step 1 Parts needed Included Washer tube Switch wiper w...

Page 7: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 7 Uninstall the upper dashboard cover from the UTV carefully...

Page 8: ...oard cover and uninstall original screw in red circle from the UTV plastic front wall and install the washer tank holder Connect the harness branch No 3 with washer motor and slide the washer tank ont...

Page 9: ...SE CALL DFK AMERICA INC 630 324 8585 9 Lead the harness branch No 1 red arrow to the right front roller cage Drill hole red circle 21mm 0 83in into the unmounted dashboard cover near the right roller...

Page 10: ...10 Uninstall the central panel from the dashboard and lead the harness branch 2 from the harness to the central panel Take out the switch blind from the central panel Pull the harness branch No 2 thro...

Page 11: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 11 Detail view of connections Fill the washer liquide to the washer tank before first usage...

Page 12: ...PLEASE CALL DFK AMERICA INC 630 324 8585 12 ELECTROINSTALLATION HEATER Parts needed included Heater with cover Bleeding valve Electric vent Tightening straps Air vent smaller Air vent bigger Smaller...

Page 13: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 13 Y coupling El Vent switch Heater switch assembly Heater harness Hot water hose...

Page 14: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 14 IMPORTANT IT IS ABSOLUTELY NECESSARY TO TAKE OUT THE RUBBER PLUGS FROM THE HEATER TUBES...

Page 15: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 15 The heater has been installed in the middle inner place under dashboard...

Page 16: ...IS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 16 Uninstall the central tunel cover from UTV s floor Secure original hot water hose with red line by pliers or cl...

Page 17: ...raps at loose ends Install the small Y coupling into the original hose and into the heater hose included Tighten all 3 straps hard and lead the water hose from the engine to the central floor tunnel I...

Page 18: ...carefull to not cut that hose too short Install the short hose and remain of the hose to the heater tubes Fix these hoses with the heater tubes by tightening straps and tighten these straps very hard...

Page 19: ...IS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 19 Uninstall original screws from UTV s plastic wall Connect harness branch No 3 with the heater connector Detail...

Page 20: ...ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 20 Connect the harness branch No 4 with the electromagnetic vent Detail view Place the heater with holder onto the UTV inner wall and a...

Page 21: ...Fix the heater holder with the UTV wall by included screws M6x30 and washers red circles Insert the tightening strap onto the hose from engine red arrow and connect that hose with electromagnetic vent...

Page 22: ...IONS PLEASE CALL DFK AMERICA INC 630 324 8585 22 Secure vertical original hot water hose with red line near the left wheel by pliers or clamps from page No 12 Cut the vertical hose between the pliers...

Page 23: ...UESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 23 Insert the Y couple into the original hole Insert the tightening strap onto the hose from heater and insert that hose onto the Y couple Tighten all...

Page 24: ...er hose near Y coupling from previous page and insert the tightening straps Install the air vent valve into the hose and fix these by straps Tighten straps very hard Drill 1 hole 11 5 14mm 0 45 0 55 i...

Page 25: ...2 from the heater to the UTV switch panel Connect the heater switch body with the harness branch No 1 Detail view Insert the switch body with the harness and with the serrated lock washer into the pre...

Page 26: ...900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 26 Fix the switch with the switch base to dashboard by nut And place the plastic had onto the switch pin View onto installe...

Page 27: ...NS PLEASE CALL DFK AMERICA INC 630 324 8585 27 Drill hole 21 mm red circle for electromagnetic vent switch Pull the harness branch No 2 throught the hole from previous page bottom picture and connect...

Page 28: ...ANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 28 Inner view onto connected swithes Lead the harness branch No 5 heater and No 4 wiper washer from harness to the fro...

Page 29: ...LL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 29 Connect the branches with the UTV electroinstallation Detail of connections Make marks onto the dashboard and drill hole 8 mm 0 31 0...

Page 30: ...A INC 630 324 8585 30 Cut the holes 56mm 2 2 in into the dashboard use hole from previous step like pivot Cut the edge carefully from inner side Repeat these steps on right dashboard side Insert the a...

Page 31: ...CA INC 630 324 8585 31 Lead air hoses to the roller cage Insert air vent smaller into the hole Insert tightening strap onto the air hose and insert the air hose onto the air vent smaller Tighten strap...

Page 32: ...he mark s centers Cut the hole s edges from inner side Insert the air hoses into the heater air tube and fix by AL selfglued tape Insert air vent straight into the holes from previous page and insert...

Page 33: ...SE CALL DFK AMERICA INC 630 324 8585 33 Stick the seal black hide line onto the UTV switch panel from inner side to upper edges and install panel back to position Cut the hole for hose into the centra...

Page 34: ...e 2 To achieve engine operating temperature depress the accelerator to increase The engine RPM This will increase the preasure and flow of the water pump forcing more coolant through the heater After...

Page 35: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 35 CAB PREVIEW...

Page 36: ...LARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 36 LEFT DOOR RIGHT DOOR Remove the original screws in blue circles from the roller cage and safe these carefull...

Page 37: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 37 Place the left door base onto the roller cage and adjust that onto the best position...

Page 38: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 38 Fix the door base with the roller cage by original screws from page No 36...

Page 39: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 39 Fix the door base with the roller cage by original screw from page No 36...

Page 40: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 40 Place the door base ledge onto the door base and onto the roller cage...

Page 41: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 41 Place the correct hinges onto the door base...

Page 42: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 42 Fix the hinges with the door base and with the door base ledge by screws washers nuts and nut covers...

Page 43: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 43 Place the door base holder onto the door base and onto the roller cage...

Page 44: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 44 Fix the door base holder with the door base to the roller cage by nuts washers and nut covers...

Page 45: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 45 Lubricate the hinge s pins and insert washer 10 onto the pins Place the door onto the hinges pins...

Page 46: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 46 Adjust the door to best position by the hinges and tighten the hinge s scres and nuts hard...

Page 47: ...RIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 47 Install door stop assembly into the door stop holder Left and right door stop holders is different don t mista...

Page 48: ...ARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 48 Uninstall originall screws in green circles from roller cage and place the door stop holder onto the roller c...

Page 49: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 49 Fix the door stop holder with the roller cage by screws and washers...

Page 50: ...0 Close the door and adjust the door stop to best position in accordance with the door lock inner mechanism If you adjust the door stop correctly and close door slowely you can hear two clear metalic...

Page 51: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 51 Loosen the door s nut in green circles and adjust the door bottom epdm ledge to best position...

Page 52: ...ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 52 Install the gas spring into the gas spring holder blue part in picture for better orientation Fix the gas spring with the holder by...

Page 53: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 53 Install the gas spring holder onto the gas spring pin...

Page 54: ...UESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 54 Adjust the gas spring holder to best position IT IS IMPORTANT TO INSTALL GAS SPRING IN SAME ORIENTATION LIKE IN PICTURE If you adjust holder more t...

Page 55: ...L QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 55 Fix the gas spring holder with the door frame by TEX screws washers and TEX covers You can take out the gas spring for easier fixation and after...

Page 56: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 56 Fix the gas spring with the holder by nut washer and nut cover...

Page 57: ...ASE CALL DFK AMERICA INC 630 324 8585 57 Uninstall these screws from the door Place the rear mirror and the mirror washer onto the door panel Fix the mirror and the washer with the door by screws from...

Page 58: ...L DFK AMERICA INC 630 324 8585 58 FRONT PANEL Uninstall original screws in blue circles from roller cage and instal screws M10x60 see page No 60 It is absolutely nessesary to make this procedure one b...

Page 59: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 59 Place the front welded holders and front bottom ledge onto the roller cage...

Page 60: ...TIONS PLEASE CALL DFK AMERICA INC 630 324 8585 60 Fix the welded holder and bottom ledge with the roller cage by screws washers nuts and nut covers on both sides Adjust the ledge and the holders to be...

Page 61: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 61 Place the front bottom outer holders onto the welded holders on both sides...

Page 62: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 62 Fix the outer holders with the welded holders by nuts washers and nut covers on both sides...

Page 63: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 63 Press the holders onto the roller cage to best position and tighten nuts correctly...

Page 64: ...0 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 64 ELECTROINSTALLATION WIPER SET View onto the wiper motor with the cover and with the middle ledge Place the washer onto the...

Page 65: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 65 Place the washer onto shorter wiper pin View onto installed washers...

Page 66: ...L DFK AMERICA INC 630 324 8585 66 Place the wiper assembly onto the front glass from inner side Insert these washers onto the wiper s pins and onto the glass from outer side Fix the wiper motor with t...

Page 67: ...IS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 67 FRONT PANEL Place the front panel with the hinges onto the roller cage s roof in accordance with the original h...

Page 68: ...INC 630 324 8585 68 Fix the front hinges with the roller cage by screws washers nuts and nut covers Adjust the front galss to best position and tighten these screws and nuts hard Spray silicone from o...

Page 69: ...ANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 69 Install the gas spring into the gas spring holders IT IS IMPORTANT TO INSTALL GAS SPRING IN SAME ORIENTATION LIKE I...

Page 70: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 70 Adjust the glass lock to correct position and fix that by included pin on both sides...

Page 71: ...900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 71 If you face any gapes between the front glass sealing and roller cage you can use second sealing for front panel included...

Page 72: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 72 Detail view...

Page 73: ...L TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 73 ELECTROINSTALLATION step 2 Lead the harness branch No 1 around the roller cage to the front wiper motor Connect the harness branch wit...

Page 74: ...on wiper switch and look on the larger wiper pin If you connect all harness connectors correctly pin is turning Find the ends of turning and install the wiper arm on correct position Fix the wiper ar...

Page 75: ...0 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 75 View onto the installed plasstic holder Insert the wiper arm hook onto the wiper latch plastic holder and press it into the...

Page 76: ...GER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 76 View onto installed wiper arm hook Connect the washer hose from the harness with the washer hose from wiper arm by in...

Page 77: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 77 REAR PANEL Insert the rear bottom ledge onto the rear bottom UTV s wall and adjust to correct position...

Page 78: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 78 Place the rear glass holders onto the rear glass...

Page 79: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 79 Install the screws and washers Into the rear glass from outer side...

Page 80: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 80 Fix the glass with the holders by screws and fast lock handles and don t tighten these...

Page 81: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 81 Place the rear panel into the rear ledge and onto the roller cage...

Page 82: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 82 Fast lock assembly explode view Fast lock handle mounted Fast lock handle tightened...

Page 83: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 83 Adjust the rear glass and the holders to best position and tighten fast lock handles...

Page 84: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 84 ROOF Place the roof side holders and roof front holder onto the roof...

Page 85: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 85 Install the screws and washers into the roof and roof holders...

Page 86: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 86 Fix the roof holders with the roof by screws and fast lock handles and don t tighten these...

Page 87: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 87 Place the roof onto the roller cage and adjust to best position...

Page 88: ...POLARIS RANGER 900 XP FOR ALL TECHNICAL QUESTIONS PLEASE CALL DFK AMERICA INC 630 324 8585 88 Adjust the roof holders to best position and tighten fast lock hande hard...