Unisteer 2009 Ranger ELECTRA-STEER User manual

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KIT NUMBER 8051790
09-10 Polaris Ranger Electra-Steer Installation Manual
Thank you for purchasing our ELECTRA-STEER 12v electric assist
power steering system. Please carefully read this instruction sheet
entirely before you begin to install the system.
Remember, before beginning installation; insure that you are in a
level well lit, organized, work area. Engage the parking brake,
disconnect the battery until power is needed and chock or block the
rear wheels to insure the vehicle is stable.

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Full refund will NOT be granted to any kits that are
damaged, scratched, or altered in any fashion.
INSTALLATION TIPS:
Due to minor variations in vehicle frames, we recommend that you
leave all the U-Joint pinch bolts loose until the motor is mounted.
Then rock the steering wheel back and forth to allow the U-Joints to
align themselves. Complete the installation by tightening these bolts.
KIT CONTENTS:
TOOLS NEEDED TO COMPLETE INSTALLATION:
• 3/8” Electric Drill
• 3/8” Drill Bit
• ½ “ Drill Bit
• Soldering Iron & Solder
• Open End Wrenches: 10mm, 13mm & 17mm
• 3/8” Drive Socket Wrench and 6” extension
• Sockets: 15/16”, 3/8”, 8mm, 10mm, 13mm & 17mm
• Wire Stripper/Cutters
• Hammer
• 50 Ft Lb Adjustable Torque Wrench
• Scribe or Marking Tool
• Heat Gun
lower shaft
545170
upper shaft
545180
wiring harness
544060
hardware packet
621050
electrical packet
620900
module
motor
bracket

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INSTALLATION OF THE ELECTRA-STEER KIT:
1. Park vehicle on a level surface and set parking brake and make sure vehicle is in
park.
2. From under the vehicle loosen the 10mm bolt that retains the stock steering shaft
to the steering rack and pinion.
3. From inside vehicle, remove all the retaining bolts that hold the dash in the
vehicle. These are normally torx bits.

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4. Remove the end cup holders on both sides of the vehicle to access the plastic
shroud.
5. Open the glove box and remove the 4 bolts retaining it in place. Remove the 4
wires at the power accessory outlet. Pay attention to how they come off, as they
need to go on the same way.
6. Remove the entire dash by pulling down and out. The driver’s side needs to come
out first and go in last.
7. After the dash is out of the vehicle, access the 8mm bolt that holds the steering
column shaft onto the steering column.
8. Remove the bolt and remove the stock steering shaft assembly.

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9. When your ready to install, note that the steering shafts are installed on the motor
and marked. The shafts need to go back onto the motor the way they came off.
10. Remove the upper shaft from the motor. Install it on the steering column shaft and
install the pinch bolt loosely.
11. Remove the lower shaft from the motor and install it on the rack and pinion. Note
this joint has a large tooth space and needs to line up only one way on the rack.
Install the 10mm bolt nut and lockwasher and leave loose.
NOTE: PINK COLOR
BANDS FACE VEHICLE
SPLINES AND WHITE
FACE MOTOR SPLINES.

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12. When both shafts are in place you are now ready to install the motor. Slide the
upper shaft onto the motor. Slide the lower shaft onto the motor noting where the
marks are on the shaft and motor.
13. Put the motor up into place on the steering column frame and locate it so that the
upper and lower shaft are in line and clearing the hole in the plastic firewall.
14. Once you are happy with the location mark the column frame and remove the
assembly so that you are able to get in to drill 2 3/8 holes in the framework.

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15. Next put the shafts back on the motor and place the bracket and motor assembly
up in place and install the provided 3/8 bolts, flat washers, and lock nuts in the
column frame and through the mount plate of the electric steer bracket. Note it
may be easier to work with if you unbolt the module from the bracket.
16. Torque the 3/8 bolts to 30 ft. lbs.
17. Tighten all the pinch bolts and lower through bolt and turn wheel back and forth
to check for binding. Once you have verified that, straighten your wheels in front
and note position of steering wheel. If it is off you may have to remove the
steering wheel center cap and nut and turn or position your wheel in correct spot.
18. Reinstall the wheel nut and torque to 35 ft lbs.
19. The wiring is simple. Plug the main harness into the module and start the wiring
procedure.
20. Run the green wire to the ignition switch where there is key on power. The green
wire also needs to run to one side of the LED light.
21. Drill a ½ “ hole in the spot of your choice where you want the light to be. Note:
Make sure that there is nothing on the backside of the dash that you will drill into.
22. Run the green wire out from the back of the dash and thru the hole for the LED.
23. The orange wire also runs out the same hole and goes to the other side of the
LED.

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24. The purple or tan wire gets a spade connector crimped on it, as does the white
wire. These wires are used for self-test procedures and may be trimmed to fit
where you want them to rest. Make sure you put them in a place where they are
accessible.
25. The heavy red wire goes out to the battery positive and needs to have the fuse
installed between the battery and the harness to prevent damage.
26. The heavy black wire needs to go to the negative side of the battery. Install the
eyelets on both the red and black wire and connect them to the battery.
27. Note: You must solder all the connections and tape or shrink tube them after
soldering is complete. Crimp connectors have been proven to cause intermittent
problems. Take your time and do it right.
28. Trim your wires to length at the LED hole and make your connections at the LED.
Snap the LED in place.

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29. You are now ready to try your system. Turn the key to the on position. The LED
light will light for 3 seconds and then go out. That is normal operation. You
should now have power assist. If the light comes on and stays on or system does
not work go to the trouble shooting section.
30. Enjoy your power assist.
In some cases the purple wire above may be substituted for a tan wire!!
The Electra-Steer Power Steering Assist Unit is intended to be used in accordance with all safety
recommendations of the original manufacturer of the vehicle as specified in the Owners Manual.
This product is intended for normal operation of the vehicle as specified by the original
manufacturer. Maval Manufacturing Inc. and Unisteer Performance Products recommend that this
product should not be used in extreme environmental conditions or in competitive activities. Maval
Manufacturing Inc. and Unisteer Performance Products do not accept liability for any malfunction,
damage, or injury incurred as a result of use of this product in extreme environmental conditions or
in competitive activities.
USE DI-ELECTRIC GREASE ON ELECTRICAL CONNECTIONS.

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Electra Steer Diagnosis Trouble Code Reading and Code Clearing
1. Verify that your trouble code light is on steady.
2. Next, take your purple or brown wire and connect it to a good clean ground. You
will have to make sure it is a solid ground to get the LED to blink or flicker and
you may have to use a jumper wire to extend the wire’s length. Once you see the
LED flicker or blink wait for LED to start blinking a code.
3. The light will flash in a sequence like 1 and then 123. This code flash would be
interpreted as a code 13. The code will repeat itself 3 times and then go to the next
code if there is one in the system. You need to wait until all the codes are read and
recorded.
4. Once you know what the codes are you can use this chart to tell where or what the
problem may be.
5. Once you have determined what the problem is and make the necessary repairs,
you can proceed to clear the codes by running a jumper wire from the white wire
with the single spade connector on it to ground.
6. Verify the ignition is off. Place the white wire to ground. Turn key on, wait 5
seconds and the light should go out. When the light goes out turn off ignition and
remove jumper wire. Once all repairs are made turn ignition on and see that light
proves out normally. This is all there is to it.
Trouble Code Problem Diagnosis
41-42-43-44- Electric motor Change Electric
45-51 Malfunction Motor
11-13-14-15 Torque Sensor Change Sensor
52-54-55 ECU Change
Malfunction Computer
22 No Engine Computer Error
Input
21-23-24 No Speed Computer Error
Signal
We welcome your suggestions & comments to make this or any of our installations better! If
you have any questions or problems regarding this product please contact us at:
1555 Enterprise Parkway
Twinsburg OH 44087
800-338-9080
WWW.UNISTEER.COM
655920
(1/9/09)
Copyright © 2009 by Maval Manufacturing Corporation All rights reserved.
No part of these materials can be reproduced or utilized in any form or by any means,
electronic or mechanical, including photocopying, recording or by any information storage
and retrieval system, without permission in writing from Maval Manufacturing Corporation.