Polaris Ranger 900 XP User manual

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INSTALLATION INSTRUCTIONS
POLARIS
RANGER 900 XP

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
2
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.
Assembly of product requires 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.
Always keep your assembly area clean, uncluttered and well lit.
Keep visitors and children a safe distance away from the assembly area. Visitors
should wear the same safety equipment described above.
Never operate your UTV with the cab doors open. Failure to properly latch the
doors before moving the vehicle could result in serious injury.
Dress for safety. DO NOT wear loose clothing, gloves, neckties or jewelry if
using power tools to assemble this product.
Insert all nut covers after you finish installation.
Never drive your UTV with the cab front window in open position.
Failure to properly latch/lock front window before driving the vehicle could result
in serious injury.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
3
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.
The recommended frequency of cleaning of polycarbonate part
is about 1 time per month or according to the actual degree 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 remove the impurities from the surface of the razor blades or other sharp
items.
Do not clean cabin when the polycarbonate plates are heated by the sun.
Do not use the squeegee, it could be scratched surface plates.
Do not clean the water current strength greater than 50 bar (WAP)
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.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
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
Hex key 5mm, 6 mm
Hole saw 56 mm Hole saw 76 mm
and 8mm
(2,2 in) (3 in)

POLARIS RANGER 900 XP
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DFK AMERICA INC.
[phone]
5
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)

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
6
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.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
7
Uninstall the upper dashboard cover from the UTV carefully.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
8
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. Lead harness (red arrow) from the washer throught the hole to the inner place in the dashboard.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
9
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.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
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 throught the hole and
connect the harness (red arrow) with the switch wiper/washer.
SEE NEXT PAGE

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
11
Detail view of connections.
Fill the washer liquide to the washer tank before first usage.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
12
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

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
13
Y coupling El. Vent switch Heater switch
assembly
Heater harness Hot water hose

POLARIS RANGER 900 XP
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DFK AMERICA INC.
[phone]
14
IMPORTANT
IT IS ABSOLUTELY NECESSARY TO TAKE OUT THE RUBBER PLUGS FROM THE HEATER TUBES!!!

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
15
The heater has been installed in the middle inner place under dashboard.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
16
Uninstall the central tunel cover from UTV’s floor.
Secure original hot water hose (with red line) by pliers or clamps.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
17
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. It is necessary to keep the heater hose(red arrow) in direction
of down and forward. Side view.
Lead the water hose (red arrow) throught the floor tunel.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
18
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. Insert the tightening strap onto the shorter hose and
install elctromagnetic vent in same orientation like in picture. Tighten that strap very hard.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
19
Uninstall original screws from UTV’s plastic wall.
Connect harness branch No.: 3 with the heater connector. Detail view.

POLARIS RANGER 900 XP
FOR ALL TECHNICAL QUESTIONS, PLEASE CALL
DFK AMERICA INC.
[phone]
20
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.