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Kolpin POLARIS RANGER 800 XP Series Installation Instructions Manual

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INSTALLATION INSTRUCTIONS
POLARIS RANGER
800 XP
4x4
6x6
.

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Summary of Contents for Kolpin POLARIS RANGER 800 XP Series

  • Page 1 INSTALLATION INSTRUCTIONS POLARIS RANGER 800 XP...

  • Page 2: Safety Instructions

    Tight the front glass holders screws with attention, if you tight these screws too hard the front glass may by crackle. Insert all nut covers after you finish installation. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.

  • Page 3: Maintance And Cleaning

    The manufacturer is not responsible for scratching the surface in case of failure to comply with the above instructions. All bolted connections of cab must be by user at regular intervals checked and tightened. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.

  • Page 4: Preparation For Installation

    Uninstall the side safety networks assembly from both sides. (In red poligon) View on to the left bottom corner. Detail onto the safety networhks holder. (In red rectangle.) Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com...
  • Page 5 POLARIS RANGER 800 XP ROOF PANEL (1-part): Place the rear roof holders and front roof holders onto the roof part of the UTV’s roller cage. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 6 POLARIS RANGER 800 XP Fix the rear roof holders with roller cage by screws, washers, nut 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 7 POLARIS RANGER 800 XP Detail view on the rear roof holder. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 8 POLARIS RANGER 800 XP Place the roof panel onto the UTV’s roller cage. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 9 POLARIS RANGER 800 XP Fix the roof panel with the roof holders to UTV’s roller cage by screws, washers, nuts and nut covers. Do not tight these screws hard yet! Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 10 METAL DOOR BASES (LEFT + RIGHT): Uninstall the upper outer original screws from the rear safe cross on both sides. Uninstall the bottom original screws from the rear UTV’s roller cage on both sides (in red ellipse). Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 11 POLARIS RANGER 800 XP Place the metal door bases onto the UTV’s roller cage from 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 12 POLARIS RANGER 800 XP Fix the roof with the metal door bases 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 13 POLARIS RANGER 800 XP 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: Rear Panel

    POLARIS RANGER 800 XP REAR PANEL: Stick seal onto the rear central part of the roller cage. 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 800 XP Pull out the safeguard films from rear polycarbonate window. Place the rear polycarbonate window onto the metal door bases Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 16 POLARIS RANGER 800 XP Fix the polycarbonate rear window with the door bases to roller cage 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 17 POLARIS RANGER 800 XP Rear panel after fixing – external view: 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 800 XP Place the rear bottom metal ledge onto the 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 19 POLARIS RANGER 800 XP Fix the rear bottom ledge with the UTV’s bottom ledge. 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 Place the bottom metal windshield ledge onto the UTV’s body from the front side of the dashboard. This ledge should lay on the UTV’s body on the rubber foam sealing. Cut off the epdm according the dashboard Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 21 Install the pin of door stop assembly into the door stop pin holder. Place the door stop pin holder onto the front ledge holder and fix these by washers, nuts and nut cover. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 22 Place the front ledge holders onto the front bottom part of the roller cage on both sides. Fix the holders with the ledge to roller cage by screws, washers, nuts and nut covers. Do not tight these screws hard yet! Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com...
  • Page 23 POLARIS RANGER 800 XP The straight side of the door stop pin holder has to be orientated on to the top (with red outline). 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 Loosen the nuts in red circles. Place the front window onto the roller cage and push it under the roof. Front glass with sealing has to be lying on the front ledge welded. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 25 POLARIS RANGER 800 XP Cut the thread M8 in the original hole (in red circle) on the upper front corner reinforcement 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 Fix the holders with the UTV’s roller cage reinforcements by washers, screws and nut covers. Tight the front glass holders screws with attention, if you tight these screws too hard the front glass may by crackle. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 27 POLARIS RANGER 800 XP Detail view onto the fixed front upper glass holder. 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 800 XP DOOR LEFT: INSTALLATION OF THE RIGHT DOOR IS IDENTICAL WITH THE INSTALLATION OF THE LEFT DOOR. Place the hinges onto the metal door base. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com...
  • Page 29 POLARIS RANGER 800 XP Fix the hinges with the metal door base by screws, washers, nut 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 30 POLARIS RANGER 800 XP Detail view on fixed hinges from outside and 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 31 POLARIS RANGER 800 XP You have to lubricate the hinge’s pins and place the door onto the hinges. 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 Adjust the door to make no gapes betwen the front roller cage, the UTV’s body and the door sealing. Distance between the door, the roof and the door metal base (yellow line) has to be simillar (from 4mm to 6mm). Adjust the pin of door stop holder. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 33 If you have problems with adjusting the pin holders, you can adjust the door hinges again to better position. Now loosen the front bottom ledge nuts and adjust the door ledge epdm (red arrows). Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com...
  • Page 34 POLARIS RANGER 800 XP Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 35 Settle EPDM of front bottom lath so that whole front bottom edge will fit tightly to the profile of dashboard. We recommend to cutting front edge of EPDM under the angle 35° for better sticking to the frame. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com...
  • Page 36 POLARIS RANGER 800 XP ELECTROINSTALLATION – WASHER SYSTEM: Overall wiring diagram (wiper, washer, heating). Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 37 800 XP Accessories for mounting the bottle washer. Bottle washer has to be placed below the driver seat near to the battery. Electrical wiring for the washer is kept in a harness. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 38 POLARIS RANGER 800 XP Connect the harness branch no.: 1 with washer pump. (detail) Uninstall the plastic cover original screw. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 39 POLARIS RANGER 800 XP Dismount the plastic cover on the cabin floor of the UTV’s body. Strech the harness throught the UTV’s floor tunnel. 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 Pull out the plastic rivet from the plastic cover. Dismount the plastic cover of the left front wheel. Lead the harness from the floor tunnel to the front battery box as the arrows show at the picture. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com...
  • Page 41 POLARIS RANGER 800 XP Next step of the leading. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 42 800 XP Pull out the plastic rivet from the central dashboard panel. Uninstall the central dashboard panel. Connect the harness branch no.:2 with main UTV’s switch (In red rectangle). Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 43 POLARIS RANGER 800 XP Detail of connection. Cut the rectangle hole into the central dashboard panel. 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 800 XP Strech the harness branch no.:3 trought the hole for switch and connect with switch „wiper/washer“ (in red rectangle). Detail of connection. 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 800 XP View from the battery box. Drill hole φ12 onto the dashboard near the right front roller cage. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 46 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. Stretch the harness branch no.:4 through the hole. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 47 POLARIS RANGER 800 XP Lead the harnes branch no.:4 around the right front part of the roller cage and around 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 48 Allow the screw in the wiper motor cover and take the cover out. Connect the harness branch no.:4 with the wiper motor. Hose connection to washer jet in the roof. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 49 Fill the water to the washer tank before starting usage. ELECTROINSTALLATION – HEATER SYSTEM: The cabin can be supplied with 2 different types of heaters – Type “A” and type “B”. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 50 ”B” Accessories for mounting the heater system for Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 51 DIESEL engine Heater is designed to be inside the glove box at the dashboard. Uninstall door of the glove box from the hinge. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 52 POLARIS RANGER 800 XP Drill 2 holes 25mm on the left side of the glove box at the dashboard. Outside view from the front side. (Holes are in red circles) Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 53 Drill the hole mm to the upper side of glove box. Insert hot water hoses and harness into the holes. (Heater type “A”) Connect the hoses with the pipes of the heater. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 54 800 XP (Heater type “A”) Connect the harness branch no.: 3 with heater (detail of connection). (Heater type “A”) Connect the harness of heater with switcher in heater cover. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com...
  • Page 55 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. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com...
  • Page 56 Insert the heater to the glove box (left side first). (Heater type “A”) Insert the heater holder onto the dashboard, drill 3 holes φ8mm, insert screw rivet and tighten. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 57 Fix the heater cover with heater holder by 4 x screw M5x20 (2 upper screws are in red circles). For placing of the electric vent cut the water tube connected to the upper pipe of the heater and insert the electric vent. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com...
  • Page 58 The vent must by in same orientation like in picture. (Heater type “A”) Connect the harness branch no.: 2 with the vent. Detail of connection. Instructions for heater type “B” Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 59 (Heater type “B”) Connect the water hose with water tube and fix these by tightening straps. (Heater type “B”) Connect the harness branch no.:1 with the heater harness (detail view.) Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 60 (Heater type “B”) Place the heater holder on position and make marks according with holes. Drill 4 holes φ8mm in dashboard according with holes on the heater holder, insert screw rivet and tighten. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 61 (Heater type “B”) Connect the harness branch no.: 2 with main switch of the UTV. Cut the hose without the electromagnetic vent and insert tightening straps onto the hose. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 62 (For both types of heater) Lead the water hoses from the battery box to the floor tunnel. Detail view on the right rear corner of the front battery box. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St.
  • Page 63 POLARIS RANGER 800 XP View onto the right bottom part of the UTV’s. (Near right front wheel). Water hoses in the floor tunnel. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com Fox Lake, WI 53933...
  • Page 64 Cut the water hose (red line) with air vent valve to correct length. Lead the water hose with electromagnetic vent (orange arrow) from tunnel to the UTV’s engine. Insert the tightening straps and T coupling into the short water hose. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 65 You may be have to disconnect the original water hose from the thermostat flange before uninstallation. You have to place the included flange rubber side (red line) on engine. (For detail of flange see pages No.:51, 52) Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com...
  • Page 66 NEXT FEW STEPS ARE FOR INSTALLATION ON DIESEL ENGINE Take out the seat from the UTV and uninstall the original screw (in red circle) from the UTV’s engine. (Detail view on next page) Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 67 Drop the screw glue on heater tube and insert the heater tube instead of the original screw and tighten very hard. Insert the tightening strap on the heater hose and insert hose on the heater tube. Tighten the strap very hard. SEE NEXT PAGE Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N.
  • Page 68 The heater will draw and retain coolant, sometimes at the expense of coolant to the engine. This can cause engine overheating if not managed properly. Kolpin Outdoors Inc. Tel: (920) 928-3118 www.kolpin.com 205 N. Depot St. E-mail: customerservice@kolpin.com...

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