Kolpin POLARIS RANGER 800 XP 4x4 Installation Instructions Manual Download

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INSTALLATION INSTRUCTIONS

POLARIS RANGER

800 XP

4x4 6x6

Summary of Contents for POLARIS RANGER 800 XP 4x4

Page 1: ...INSTALLATION INSTRUCTIONS POLARIS RANGER 800 XP 4x4 6x6...

Page 2: ...s use of hand or power tools If you are not experienced in using these types of tools have product dealer do the install for you Some parts contain sharp edges wear protective gloves if necessary Alwa...

Page 3: ...of pollution Do not use 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 remov...

Page 4: ...I 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com PREPARATION FOR INSTALLATION Uninstall the side safety networks assembly from both sides In red poligon View on to the left bo...

Page 5: ...in Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com ROOF PANEL 1 part Place the rear roof holders and front roof holders onto the roof pa...

Page 6: ...GER 800 XP 6 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Fix the rear roof holders with roller cage by screws washers nut and...

Page 7: ...POLARIS RANGER 800 XP 7 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Detail view on the rear roof holder...

Page 8: ...POLARIS RANGER 800 XP 8 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Place the roof panel onto the UTV s roller cage...

Page 9: ...Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Fix the roof panel with the roof holders to UTV s roller cage by screws washers nuts and nut cov...

Page 10: ...8 www kolpin com E mail customerservice kolpin com Detail views onto the roof holders METAL DOOR BASES LEFT RIGHT Uninstall the upper outer original screws from the rear safe cross on both sides Unins...

Page 11: ...RANGER 800 XP 11 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Place the metal door bases onto the UTV s roller cage from both...

Page 12: ...ARIS RANGER 800 XP 12 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Fix the roof with the metal door bases by screws on both si...

Page 13: ...POLARIS RANGER 800 XP 13 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com...

Page 14: ...S RANGER 800 XP 14 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com REAR PANEL Stick seal onto the rear central part of the roller...

Page 15: ...utdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Pull out the safeguard films from rear polycarbonate window Place the rear polycarbonate...

Page 16: ...Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Fix the polycarbonate rear window with the door bases to roller cage by screws wa...

Page 17: ...POLARIS RANGER 800 XP 17 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Rear panel after fixing external view...

Page 18: ...LARIS RANGER 800 XP 18 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Place the rear bottom metal ledge onto the correct positio...

Page 19: ...POLARIS RANGER 800 XP 19 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Fix the rear bottom ledge with the UTV s bottom ledge...

Page 20: ...0 928 3118 www kolpin com E mail customerservice kolpin com FRONT PANEL 1 part Place the bottom metal windshield ledge onto the UTV s body from the front side of the dashboard This ledge should lay on...

Page 21: ...St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Install the pin of door stop assembly into the door stop pin holder Place the door stop pin holder onto the front...

Page 22: ...3 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com 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 c...

Page 23: ...23 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com The straight side of the door stop pin holder has to be orientated on to the...

Page 24: ...St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Loosen the nuts in red circles Place the front window onto the roller cage and push it under the roof Front glas...

Page 25: ...Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Cut the thread M8 in the original hole in red circle on the upper front corner re...

Page 26: ...e the front upper glass holders left and right onto the correct position Fix these holders with glass by screws washers nuts and nut covers Fix the holders with the UTV s roller cage reinforcements by...

Page 27: ...POLARIS RANGER 800 XP 27 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Detail view onto the fixed front upper glass holder...

Page 28: ...s Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com DOOR LEFT INSTALLATION OF THE RIGHT DOOR IS IDENTICAL WITH THE INSTALLATION OF THE LEFT DOOR Pl...

Page 29: ...NGER 800 XP 29 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Fix the hinges with the metal door base by screws washers nut and...

Page 30: ...POLARIS RANGER 800 XP 30 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Detail view on fixed hinges from outside and from inside...

Page 31: ...ANGER 800 XP 31 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com You have to lubricate the hinge s pins and place the door onto th...

Page 32: ...118 www kolpin com E mail customerservice kolpin com 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 m...

Page 33: ...ustomerservice kolpin com If you close the door slowely and holder has been adjusted correctly you can hear clear metallic click If you have problems with adjusting the pin holders you can adjust the...

Page 34: ...POLARIS RANGER 800 XP 34 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com...

Page 35: ...933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Settle EPDM of front bottom lath so that whole front bottom edge will fit tightly to the profile of dashboard We recommend to cutt...

Page 36: ...GER 800 XP 36 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com ELECTROINSTALLATION WASHER SYSTEM Overall wiring diagram wiper wash...

Page 37: ...St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Accessories for mounting the bottle washer Bottle washer has to be placed below the driver seat near to the batte...

Page 38: ...38 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Connect the harness branch no 1 with washer pump detail Uninstall the plastic...

Page 39: ...in Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Dismount the plastic cover on the cabin floor of the UTV s body Strech the harness th...

Page 40: ...53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Pull out the plastic rivet from the plastic cover Dismount the plastic cover of the left front wheel Lead the harness from the...

Page 41: ...POLARIS RANGER 800 XP 41 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Next step of the leading...

Page 42: ...St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Pull out the plastic rivet from the central dashboard panel Uninstall the central dashboard panel Connect the har...

Page 43: ...NGER 800 XP 43 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Detail of connection Cut the rectangle hole into the central dashb...

Page 44: ...s Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Strech the harness branch no 3 trought the hole for switch and connect with switch wiper washer...

Page 45: ...XP 45 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com View from the battery box Drill hole 12 onto the dashboard near the right...

Page 46: ...920 928 3118 www kolpin com E mail customerservice kolpin com 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 origina...

Page 47: ...0 XP 47 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Lead the harnes branch no 4 around the right front part of the roller cag...

Page 48: ...Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Allow the screw in the wiper motor cover and take the cover out Connect the harness branch no 4 with the wi...

Page 49: ...St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Fill the water to the washer tank before starting usage ELECTROINSTALLATION HEATER SYSTEM The cabin can be suppl...

Page 50: ...to the which type of heater is concerned step then the step is the same for both types Accessories for mounting the heater system for heater type A harness heating holder air vent valve Y coupling hea...

Page 51: ...w kolpin com E mail customerservice kolpin com harness heating holder Y coupling heater tightening strap screw rivets flange for PETROL engine air vent valve heater tube for DIESEL engine Heater is de...

Page 52: ...oors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Drill 2 holes 25mm on the left side of the glove box at the dashboard Outside view from the...

Page 53: ...epot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Drill the hole mm to the upper side of glove box Insert hot water hoses and harness into the holes Connect t...

Page 54: ...N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Connect the harness branch no 3 with heater detail of connection Heater type A Connect the harness of he...

Page 55: ...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 Co...

Page 56: ...www kolpin com E mail customerservice kolpin com Place the bottom part of heater holder onto the position outlines in red Insert the heater to the glove box left side first Heater type A Insert the h...

Page 57: ...28 3118 www kolpin com E mail customerservice kolpin com Fix the heater cover with heater holder by 4 x screw M5x20 2 upper screws are in red circles Heater type A For placing of the electric vent cut...

Page 58: ...928 3118 www kolpin com E mail customerservice kolpin com Fix the water tube with vent by tightening strap The vent must by in same orientation like in picture Heater type A Connect the harness branch...

Page 59: ...pin com E mail customerservice kolpin com Connect the water hose with electric vent and fix these by tightening straps Heater type B Connect the water hose with water tube and fix these by tightening...

Page 60: ...e WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com Place the heater holder on position and make marks according with holes Heater type B Drill 4 holes 8mm in dashboard accord...

Page 61: ...w kolpin com E mail customerservice kolpin com Heater type B Connect the harness branch no 1 with main switch of the UTV Heater type A Connect the harness branch no 2 with main switch of the UTV Heate...

Page 62: ...om E mail customerservice kolpin com Insert the air vent valve in red circle into the both end of the hose and tight the straps hard For both types of heater Lead the water hoses from the battery box...

Page 63: ...63 Kolpin Outdoors Inc 205 N Depot St Fox Lake WI 53933 Tel 920 928 3118 www kolpin com E mail customerservice kolpin com View onto the right bottom part of the UTV s Near right front wheel Water hose...

Page 64: ...928 3118 www kolpin com E mail customerservice kolpin com 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 t...

Page 65: ...ening straps on both ends Insert the Y coupling red ellipse into the original water hose and tight the straps very hard Take out the pliers from the original water hose NEXT FEW STEPS ARE FOR INSTALLA...

Page 66: ...engine and fix these by 2 screws M6x50 and washers Insert tightening strap on the water hose and connect the hose with tube on the flange and tighten the strap very hard You can install back the orig...

Page 67: ...w kolpin com E mail customerservice kolpin com Detail view 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...

Page 68: ...on and wait for the maximum temperature When the cooling liquid starts to leak from the air vent valve close the valve Turn off heater and add more cooling liquid to the cooling circuit if need it In...

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