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Kolpin POLARIS RANGER Installation Instructions Manual

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INSTALLATION INSTRUCTIONS
POLARIS RANGER
400 H.O.
.

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Summary of Contents for Kolpin POLARIS RANGER

  • Page 1 INSTALLATION INSTRUCTIONS POLARIS RANGER 400 H.O.

  • Page 2: Safety Instructions

    POLARIS RANGER 400H.O. SAFETY INSTRUCTIONS Warning: Failure to heed all safety and operating instructions and warnings regarding use of this product can result in serious bodily injury. READ PROPERLY COMPLETE ASSEMBLY INSTRUCTIONS BEFORE STARTING OF ASSEMBLY Install all parts indicated in assembly instructions. Failure to fully assemble product before use could result in personal injury.

  • Page 3: Maintenance And Cleaning

    POLARIS RANGER 400H.O. MAINTENANCE AND CLEANING To clean polycarbonate surface use soapy water solution or other subtle means. Dirt and dust wash by gently water stream and swipe only with wet or damp means in the direction from top to bottom.
  • Page 4 POLARIS RANGER 400H.O. Place the roof panel on to the roller cage from above and don´t fix it. METAL DOOR BASES Tel: (920) 928-3118 Kolpin Outdoors Inc. www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 5 POLARIS RANGER 400H.O. Place the metal door bases on to the roller cage from both sides. The upper end of the door bases belongs under the roof panel. Press gently the door bases onto the roller cage. Screw together the door bases with the roof panel using the prepared holes.

  • Page 6: Rear Panel

    POLARIS RANGER 400H.O. REAR PANEL Place the polycarbonate rear panel on to the metal door bases from behind. The upper end of the rear panel belongs under the roof panel. Tel: (920) 928-3118 Kolpin Outdoors Inc. www.kolpin.com 205 N. Depot St.
  • Page 7 POLARIS RANGER 400H.O. Screw the bottom part of the rear panel to the roller cage in the bottom corners on both sides with bolts M8x80 and nut M8 (see the red circles).Place the rear holder onto the door bases. Fix the panel with bolts M8x30 and nuts M8 and place the plastic covers on the nuts from inside.
  • Page 8 POLARIS RANGER 400H.O. Place the bottom metal rear ledge on to the body from behind. Tel: (920) 928-3118 Kolpin Outdoors Inc. www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 9 POLARIS RANGER 400H.O. Fix the ledge with bolts M6x20 and nuts M6 and two washers. Tel: (920) 928-3118 Kolpin Outdoors Inc. www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 10 POLARIS RANGER 400H.O. FRONT PANEL MOVABLE 1. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 11 POLARIS RANGER 400H.O. Place the bottom metal windshield ledge onto the body from the front side of the dashboard. This ledge should lay on the body on the rubber foam sealing. Install the pin of door stop assembly into the door stop pin holder.
  • Page 12 POLARIS RANGER 400H.O. (Door stop pin holder left is the same with right just opposite bend.) The ledge should be fixed to the roller cage with the holders on both sides. These holders contain the door lock stoppers. Kolpin Outdoors Inc.
  • Page 13 POLARIS RANGER 400H.O. Fix the ledge with bolts M8x35 and nuts M8 and place the plastic covers on the nuts from inside. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 14 POLARIS RANGER 400H.O. Detail view to the right door stop. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 15 POLARIS RANGER 400H.O. Cut the tightening straps in the hinges and place the hinge washers onto the front window hinges and place the upper front ledge onto the hinge washers. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 16 POLARIS RANGER 400H.O. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 17 POLARIS RANGER 400H.O. Fix the hinges with the front upper ledge by screws, washers, nuts and nut covers. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 18 POLARIS RANGER 400H.O. Uninstall the screws from rear roof corner on both sides. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 19 POLARIS RANGER 400H.O. Take up the front part of the roof. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 20 POLARIS RANGER 400H.O. Place the front window with the ledge onto the roller cage and adjust to correct position. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 21 POLARIS RANGER 400H.O. Place the front ledge holders onto the roller cage to correct position. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 22 POLARIS RANGER 400H.O. Fix the roof with the front upper ledge and with the holders to the roller cage by screws, washers, nuts and nut covers. Adjust the front panel to best position and tighten these screws gently. Kolpin Outdoors Inc.
  • Page 23 POLARIS RANGER 400H.O. ROOF 2. Place the rear roof holders onto the roller cage and the roof. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 24 POLARIS RANGER 400H.O. Fix the roof with the roof holders to the roller cage by screws, washers, nuts and nut covers. Don’t tighten these screws yet. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 25 POLARIS RANGER 400H.O. FRONT PANEL MOVABLE 2. Insert the front glass lock’s pins (red) into the glass locks and glass lock holders on both sides. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 26 POLARIS RANGER 400H.O. Allow the glass lock screws (in red circle) on both sides and close the front glass correctly. Adjust the glass lock’s metal holders on both sides to best position, tighten screws (in red circle) and take out the glass lock’s pins (red). If you have any gapes between the window bottom seal and front bottom ledge, you can repair it by adjusting the holder.
  • Page 27 POLARIS RANGER 400H.O. Open the front glass and insert the gas springs to holders on both sides. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 28 POLARIS RANGER 400H.O. Insert the gas spring’s bottom pins in the gas spring metal holders and fix these by nuts and nut covers. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 29 POLARIS RANGER 400H.O. ROOF Fix the door bases with the roof by screws on both sides. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 30 POLARIS RANGER 400H.O. Fix the roof with the rear window and with the door bases by screws, washers, nuts and nut covers. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 31 POLARIS RANGER 400H.O. DOOR LEFT AND DOOR RIGHT Place the right door hinges onto the right door base on correct position. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 32 POLARIS RANGER 400H.O. Fix the door hinges by screws M8x30 and nuts M8 and place the plastic covers on the nuts from inside. Do not tighten screws hard yet. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 33 POLARIS RANGER 400H.O. DOOR ASSEMBLY Lubricate the hinge’s pins and insert the door on the hinges (see the picture below) Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 34 POLARIS RANGER 400H.O. Adjust the door by the door hinges to best position (no gapes between doors, roof and UTV‘ body). Close the door slowly and insert the door stop pin into the door lock.Adjust the pin holder to best position and tight the nuts. If you close the door slowly now and the door stop pin holder is adjust correctly you can hear clear metalic click.
  • Page 35 POLARIS RANGER 400H.O. doors to close the gaps between the polycarbonate doors and the floor. The doors should seal now all-around well, there mustn’t be any gap between the body and the doors. If any gap appears, repeat the positioning of the doors at hinges.
  • Page 36 POLARIS RANGER 400H.O. If you have some problems with the the door rear bottom ledge installation you can adjust that. SEE NEXT PAGES Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 37 POLARIS RANGER 400H.O. Take out the nut covers and allow the nuts (in red circles). Save the cover carefolly, you need these later. You may be have to take out the seal from the door ledge. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com...
  • Page 38 POLARIS RANGER 400H.O. Adjust the ledge to best position and tighten nuts gently. Place the seal onto the ledges and close the door few times. If the ledge is adjusted correctly, tighten the nuts and place the nut covers INSTALLATION OF THE LEFT DOOR IS IDENTICAL WITH THE INSTALLATION OF THE RIGHT DOOR Kolpin Outdoors Inc.
  • Page 39 POLARIS RANGER 400H.O. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 40 POLARIS RANGER 400H.O. ELECTROINSTALLATION – WASHER SYSTEM: Overall wiring diagram (wiper, washer, heating). Accessories for mounting the bottle washer. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 41 POLARIS RANGER 400H.O. Bottle washers placed in front of the cart through the bracket bolt to the truck frame. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 42 POLARIS RANGER 400H.O. DIP SWITCH no. 510: Connection on pins: 2, 4, 5 – yellow+black wire, minus pole – yellow+green, washer motor – green, wiper motor Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 43 POLARIS RANGER 400H.O. CONNECTION: WIPER MOTOR 12V, 175° Connect the wiring harness for motor and washer to the UTV. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 44 POLARIS RANGER 400H.O. Position of switches for controlling the wiper motor (first position) and washer (second position). Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 45 POLARIS RANGER 400H.O. Continue with the wiring inside the dashboard and lead it up on the left side of the roller cage to the wiper motor Runs along the original wiring harness in the dashboard. There is a washer hose inside the wiring harness.
  • Page 46 POLARIS RANGER 400H.O. Detailed schematic diagram of the motor wiring harness: Hose connection to washer jet in the roof. Fill the water to the washer tank before starting usage. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 47 POLARIS RANGER 400H.O. ELECTROINSTALLATION – HEATER SYSTEM: Accessories for mounting the heater system harness heater cover “Y” coupling heater tightening strap screw rivets Air vent valve electromagnetic vent Heater flange Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 48 POLARIS RANGER 400H.O. Heater is designed to be inside the glove box at the dashboard. Uninstall door of the glove box from the hinge. Drill 2 holes ø25mm on the left side of the glove box at the dashboard. Kolpin Outdoors Inc.
  • Page 49 POLARIS RANGER 400H.O. Outside view from the front side. (Holes are in red circles) Drill hole ø20mm to the upper side of glove box. Insert hot water hoses and harness into the holes. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 50 POLARIS RANGER 400H.O. Connect the hoses with the pipes of the heater. Connect the harness branch no.: 3 with heater (detail of connection). Connect the harness of heater with switcher in heater cover. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 51 POLARIS RANGER 400H.O. Pull out the plastic button from switch. Uninstall the nut from switch and pull the switch out from the cover. View on to the switch assembly. Connect the heater harness with switch. View on to connected harness. Install switcher back into the heater cover.
  • Page 52 POLARIS RANGER 400H.O. Connect the harness branch no.: 4 to the electric vent switch on the heater cover. When the swith is backlit, electric vent is turn off and hot water from engine cooling don’t run in heater. Press the heater holder onto the dashboard, drill 3 holes φ8mm, insert screw rivet and tighten.
  • Page 53 POLARIS RANGER 400H.O. For placing of the electric vent cut the water tube connected to the upper pipe of the heater and insert the electric vent. Fix the water tube with vent by tightening strap. The vent must by in same orientation like in picture.
  • Page 54 POLARIS RANGER 400H.O. Cut the hose without the electromagnetic vent and insert tightening straps onto the hose. Insert the air vent valve into the both end of the hose and tight the straps hard. Detail view. Principle involved: Hot water heating system connected to the primary (short) circuit of the engine cooling.
  • Page 55 POLARIS RANGER 400H.O. Unistall the thermostat flange and thermostat (violet arrow) from the engine body and place the heater flange (red arrow) onto correct position. The heater flange seal must lie on the engine body. Place the thermostat in original orientation onto the heater flange and install the thermostat flange.

  • Page 56: Important Notice

    POLARIS RANGER 400H.O. Important notice: 1. Before the first turning on the hot water heater it is necessary to check the tightness of the cooling circuit of the hot water heater. 2. If necessary add more cooling liquid to the cooling circuit.