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Polaris Ranger 900 XP Installation Instructions Manual
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Polaris Ranger 900 XP Installation Instructions Manual

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INSTALLATION INSTRUCTIONS
POLARIS
RANGER 900 XP
.

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Summary of Contents for Polaris Ranger 900 XP

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

  • Page 2: Safety Instructions

    POLARIS RANGER 900 XP 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 900 XP 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 900 XP TOOLS NEEDED Not included Ratchet handle Socket beg 17 mm Socket beg 13 mm (0,67 in) (0,51 in) For tightening straps Metric wrench 13mm, Utility knife Socket beg 8 mm (0,31 in) 17mm Hex key 5mm, 6 mm...
  • Page 5 POLARIS RANGER 900 XP Drill ø 2,5-4mm Drill ø 8mm Drill ø 12 mm ( 0,1- 0,16 in) (0,31-0,33 in) (0,5 in) Drill ø 21mm (0,83 in) FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...

  • Page 6: Preparation For Installation

    POLARIS RANGER 900 XP PREPARATION FOR 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/washer/off Harness and washer tank Wiper harness Washer tank has been placed under the front dashboard cover.
  • Page 7 POLARIS RANGER 900 XP Uninstall the upper dashboard cover from the UTV carefully. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 8 POLARIS RANGER 900 XP Take out the front dashboard 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 onto the washer tank holder.
  • Page 9 POLARIS RANGER 900 XP Lead the harness branch No.: 1 (red arrow) to the right front roller cage. Drill hole(red circle) ø 21mm (0,83in) into the unmounted dashboard cover near the right roller cage and stretch the harness branch throught the hole.
  • Page 10 POLARIS RANGER 900 XP 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 throught the hole and connect the harness (red arrow) with the switch wiper/washer.
  • Page 11 POLARIS RANGER 900 XP Detail view of connections. Fill the washer liquide to the washer tank before first usage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 12 POLARIS RANGER 900 XP ELECTROINSTALLATION – HEATER Parts needed (included) Heater with cover Bleeding valve Electric vent Tightening straps Air vent smaller Air vent bigger Smaller, bigger and large Hot air hose AL tape Y coupling FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC.
  • Page 13 POLARIS RANGER 900 XP Y coupling El. Vent switch Heater switch assembly Heater harness Hot water hose FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 14 POLARIS RANGER 900 XP IMPORTANT IT IS ABSOLUTELY NECESSARY TO TAKE OUT THE RUBBER PLUGS FROM THE HEATER TUBES!!! FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 15 POLARIS RANGER 900 XP The heater has been installed in the middle inner place under dashboard. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 16 POLARIS RANGER 900 XP Uninstall the central tunel cover from UTV’s floor. Secure original hot water hose (with red line) by pliers or clamps. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 17 POLARIS RANGER 900 XP Cut the hose between pliers and insert tightening straps 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.
  • Page 18 POLARIS RANGER 900 XP Cut the water hose (with red line) to correct length, be 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 POLARIS RANGER 900 XP Uninstall original screws from UTV’s plastic wall. Connect harness branch No.: 3 with the heater connector. Detail view. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 20 POLARIS RANGER 900 XP Connect the harness branch No.: 4 with the electromagnetic vent. Detail view. Place the heater with holder onto the UTV inner wall and adjust to correct position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC.
  • Page 21 POLARIS RANGER 900 XP 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. Tighten strap very hard. Lead the water hose (violet arrows) from heater to the front left wheel.
  • Page 22 POLARIS RANGER 900 XP 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 an insert the tightening straps onto the hose.
  • Page 23 POLARIS RANGER 900 XP 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 straps very hard and take out the pliers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC.
  • Page 24 POLARIS RANGER 900 XP Cut the heater 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 ø 11,5-14mm (0,45-0,55 in) and 2 holes ø 2,5-4 mm ( 0,1- 0,16 in) into the dashboard in accordance with the ventilator switch base.
  • Page 25 POLARIS RANGER 900 XP Lead the harness branches No.:1 and 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 prepared hole from page No.: 20(upper picture) from inside.
  • Page 26 POLARIS RANGER 900 XP Fix the switch with the switch base to dashboard by nut. And place the plastic had onto the switch pin. View onto installed heater swith. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 27 POLARIS RANGER 900 XP Drill hole ø 21 mm (red circle) for electromagnetic vent switch. Pull the harness branch No.: 2 throught the hole from previous page (bottom picture) and connect the branch with the switch. Detail of connection. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC.
  • Page 28 POLARIS RANGER 900 XP Inner view onto connected swithes. Lead the harness branch No.: 5 heater and No.: 4 wiper washer from harness to the front space. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 29 POLARIS RANGER 900 XP Connect the branches with the UTV’ electroinstallation. Detail of connections. Make marks onto the dashboard and drill hole ø8 mm (0,31-0,33 in)into the marks center. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 30 POLARIS RANGER 900 XP Cut the holes ø56mm (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 air hose into the heater air tube and fix by included “AL” self glued tape.
  • Page 31 POLARIS RANGER 900 XP 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 hard. Place the template onto the dashboard and adjust to best position.
  • Page 32 POLARIS RANGER 900 XP Make marks in accordance with the templateand and cut the holes ø76mm (3 in) into the 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 the air hose onto the air vent.
  • Page 33 POLARIS RANGER 900 XP 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 central floor tunel cover and instal cover back to position.
  • Page 34 POLARIS RANGER 900 XP It is absolutely necessary to bleed the air out of the UTV’s engine cooling system. Incomplete bleeding of cooling system can result in engine damage. If you don’t have sufficient experience with this process, we strongly recommend professional service technician assistance.
  • Page 35 POLARIS RANGER 900 XP CAB PREVIEW FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 36 POLARIS RANGER 900 XP LEFT DOOR + RIGHT DOOR Remove the original screws (in blue circles) from the roller cage, and safe these carefully FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 37 POLARIS RANGER 900 XP Place the left door base onto the roller cage and adjust that onto the best position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 38 POLARIS RANGER 900 XP Fix the door base with the roller cage by original screws from page No.: 36. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 39 POLARIS RANGER 900 XP Fix the door base with the roller cage by original screw from page No.: 36. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 40 POLARIS RANGER 900 XP Place the door base ledge onto the door base and onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 41 POLARIS RANGER 900 XP Place the correct hinges onto the door base. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 42 POLARIS RANGER 900 XP Fix the hinges with the door base and with the door base ledge by screws, washers, nuts and nut covers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 43 POLARIS RANGER 900 XP Place the door base holder onto the door base and onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 44 POLARIS RANGER 900 XP Fix the door base holder with the door base to the roller cage by nuts, washers and nut covers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 45 POLARIS RANGER 900 XP Lubricate the hinge’s pins and insert washer 10 onto the pins. Place the door onto the hinges pins. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 46 POLARIS RANGER 900 XP Adjust the door to best position by the hinges and tighten the hinge’s scres and nuts hard. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 47 POLARIS RANGER 900 XP Install door stop assembly into the door stop holder. Left and right door stop holders is different don’t mistaken. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 48 POLARIS RANGER 900 XP Uninstall originall screws (in green circles) from roller cage and place the door stop holder onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 49 POLARIS RANGER 900 XP Fix the door stop holder with the roller cage by screws and washers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 50 POLARIS RANGER 900 XP 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 click.
  • Page 51 POLARIS RANGER 900 XP Loosen the door’s nut (in green circles) and adjust the door bottom epdm ledge to best position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 52 POLARIS RANGER 900 XP Install the gas spring into the gas spring holder (blue part in picture for better orientation). Fix the gas spring with the holder by nut, washer and nut cover. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC.
  • Page 53 POLARIS RANGER 900 XP Install the gas spring holder onto the gas spring pin. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 54 POLARIS RANGER 900 XP 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 to rear side, door is open to bigger angel.) FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC.
  • Page 55 POLARIS RANGER 900 XP 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 that, place gas spring back to holder.) FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC.
  • Page 56 POLARIS RANGER 900 XP Fix the gas spring with the holder by nut, washer and nut cover. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 57 POLARIS RANGER 900 XP 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 previous step. The right door installation is similar.

  • Page 58: Front Panel

    POLARIS RANGER 900 XP 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 by one, othervise roller cage might lose its original position.
  • Page 59 POLARIS RANGER 900 XP Place the front welded holders and front bottom ledge onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 60 POLARIS RANGER 900 XP 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 best position and tighten screws and nuts hard.
  • Page 61 POLARIS RANGER 900 XP Place the front bottom outer holders onto the welded holders on both sides. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 62 POLARIS RANGER 900 XP Fix the outer holders with the welded holders by nuts, washers and nut covers on both sides. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 63 POLARIS RANGER 900 XP Press the holders onto the roller cage to best position and tighten nuts correctly. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 64 POLARIS RANGER 900 XP ELECTROINSTALLATION – WIPER SET View onto the wiper motor with the cover and with the middle ledge. Place the washer onto the wiper longer pin. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 65 POLARIS RANGER 900 XP Place the washer onto shorter wiper pin. View onto installed washers. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 66 POLARIS RANGER 900 XP 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 the front glass by included nuts and tighten these correctly.
  • Page 67 POLARIS RANGER 900 XP FRONT PANEL Place the front panel with the hinges onto the roller cage’s roof in accordance with the original holes. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 68 POLARIS RANGER 900 XP 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 outer side into the roller cage gapes (in green circle) in both sides of UTV.
  • Page 69 POLARIS RANGER 900 XP Install the gas spring into the gas spring holders. IT IS IMPORTANT TO INSTALL GAS SPRING IN SAME ORIENTATION LIKE IN PICTURE FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 70 POLARIS RANGER 900 XP Adjust the glass lock to correct position and fix that by included pin on both sides. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 71 POLARIS RANGER 900 XP If you face any gapes between the front glass sealing and roller cage, you can use second sealing for front panel (included). SEE NEXT PAGE FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 72 POLARIS RANGER 900 XP Detail view FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 73 POLARIS RANGER 900 XP ELECTROINSTALLATION step 2. Lead the harness branch No.: 1 around the roller cage to the front wiper motor. Connect the harness branch with the wiper motor connector. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC.
  • Page 74 POLARIS RANGER 900 XP Now you can turn 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.
  • Page 75 POLARIS RANGER 900 XP View onto the installed plasstic holder. Insert the wiper arm hook onto the wiper latch plastic holder and press it into the correct position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 76 POLARIS RANGER 900 XP View onto installed wiper arm hook. Connect the washer hose from the harness with the washer hose from wiper arm by included tube. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 77 POLARIS RANGER 900 XP REAR PANEL Insert the rear bottom ledge onto the rear bottom UTV’s wall and adjust to correct position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 78 POLARIS RANGER 900 XP Place the rear glass holders onto the rear glass. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 79 POLARIS RANGER 900 XP Install the screws and washers Into the rear glass from outer side. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 80 POLARIS RANGER 900 XP Fix the glass with the holders by screws and fast-lock handles and don’t tighten these. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 81 POLARIS RANGER 900 XP Place the rear panel into the rear ledge and onto the roller cage. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 82 POLARIS RANGER 900 XP Fast-lock assembly (explode view). Fast-lock handle mounted. Fast-lock handle tightened. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 83 POLARIS RANGER 900 XP Adjust the rear glass and the holders to best position and tighten fast-lock handles. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 84 POLARIS RANGER 900 XP ROOF Place the roof side holders and roof front holder onto the roof. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 85 POLARIS RANGER 900 XP Install the screws and washers into the roof and roof holders. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 86 POLARIS RANGER 900 XP Fix the roof holders with the roof by screws and fast-lock handles and don’t tighten these. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 87 POLARIS RANGER 900 XP Place the roof onto the roller cage and adjust to best position. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...
  • Page 88 POLARIS RANGER 900 XP Adjust the roof holders to best position and tighten fast-lock hande hard. FOR ALL TECHNICAL QUESTIONS, PLEASE CALL DFK AMERICA INC. (630) 324-8585...