Body / Steering / Suspension
Contents
1. II always be positioned as shown in the illustration FULLY COMPRESSED SHOCK PISTON S SS REBOUND VALVE STACK W cud NS COMPRESSION VALVE STACK ROD FULLY EXTENDED SHOCK ROD Piston Orientation The face of the piston with the greater number of relief ports will always face the rebound valve stack Relief Port Faces Rebound Stack Faces Compression Stack 5 45 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Pola ris Sales Inc BODY STEERING SUSPENSION Walker Evans Shock Disassembly 5 Using a snap ring pliers remove the retaining ring from the reservoir IMPORTANT To prevent damage or marks to the shock the use of soft jaws on a vise is recommended A WARNING Walker Evans shocks contain high pressure nitrogen gas Extreme caution must be used while handling and working with Walker Evans shocks and related high pressure service equipment The pressure must be released from the shock before disassembly It is strongly recommended you wear safety glasses and ear protection during these procedures 1 Clean and carefully remove shock from the vehicle seb lt 3 o lt 2 3 2 o lt o o lt 2 Secure shock2. 5 41 SECF LEVELING SUSPENSION HD 4 etn ote Ru Rh ar etm e ehm sas 5 42 NIVOMAT SHOCK OPERATION DISPOSAL REPLACEMENT 5 42 WALKER EVANS SHOCK EXPLODED VIEW 5 43 WALKER EVANS SHOCK SERVICE 5 44 RECOMMENDED SERVICE INTERVALS 555 tent b ER MEER Rc 5 44 FRONT REAR SHOCK SERVICE INFORMATION 5 44 WALKER EVANS SHOCK REBUILD 5 45 SPECIAL TOOLS 2 acute eR ORDIN EUN M Led UE Decal cau Un 5 45 VALVE SHIM ARRANGEMENT vac crac ee Rer ee ku aki hore oca 5 45 PISTON ORIENTATION dat diets iei eee 5 45 WALKER EVANS SHOCK DISASSEMBLY 5 46 WALKER EVANS SHOCK ASSEMBLY et ht bested 5 48 5 1 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION TORQUE SPECIFICATIONS SPECIAL TOOLS ITEM TORQUE VALUE TOOL DESCRIPTION PART NUMBER 1198 Um Shock Spanner Wrench 2871095 Front Frame to Rear Frame Support Fasteners CREW 38 40 ft Ibs 52 54 Nm Shock Spanner Wrench W E 2870803 Main Erameto Rear Fiame massa Shock Spring Compressor Tool 2870623 Fasteners 6x6 Multi Function Pliers 2876389 Front Upper Lower 30 ft Ibs 41 Nm A Arm Bolts Mid Up
3. A 4 Bearing Spacer AN lt S 7 ft Ibs 10 Nm Thin Washer 1 Thick Washers My Thin Washer Qi Steering Shaft Oil Locking 16 Nm Shock Asm 40 ft Ibs 54 Nm 12 14 ft Ibs 16 19 Nm Gear Box am i Asm A Ew d amp b oS E e e 40 ft Ibs 54 Nm oe 1 Tie Rod Rod End Sue 12 14 ft Ibs 16 19 Nm Cotter Pin 5 25 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Steering Wheel Removal Non EPS Models CAUTION This procedure should NOT be used on EPS models Using this procedure on an EPS model can permanently damage the EPS unit and cause a Power Steering Fault 1 Remove the steering wheel cap 2 Loosen the nut and back it half way off the steering shaft 3 With a glove on your hand place it under the steering wheel Lift upward on the inner portion of the steering wheel while using a hammer to strike the steering shaft nut IMPORTANT If the steering wheel will not pop loose proceed to Steering Shaft Removal 4 Once the steering wheel pops loose completely remove the nut and lift the steering wheel off the shaft 5 26 Steering Shaft Removal Non EPS Models Remove the pinch bolt retaining the lower portion of the steering shaft to the steering gear box assem
4. 5 Using a soft face hammer tap on bearing carrier to loosen the upper A arm ball joint end while lifting upward on the upper A arm Completely remove the ball joint end from the bearing carrier 6 Loosen and remove the upper A arm through bolt fasteners C and remove the upper A arm from the vehicle 7 Examine A arm bushings and pivot tubes see Exploded View Replace if worn Discard hardware A WARNING The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 8 If notreplacing the A arm thoroughly clean the A arm and pivot tubes 9 Install new ball joint into A arm Refer to Ball Joint Replacement section 10 Insert new A arm bushings and pivot tubes into new A arm 11 Install new upper A arm assembly onto vehicle frame Torque new bolts to 30 ft Ibs 41 Nm 12 Insert upper A arm ball joint end into the bearing carrier Install the upper ball joint pinch bolt B into the bearing carrier and torque bolt to 23 ft Ibs 31 Nm 13 Attach shock to A arm with fastener A Torque lower shock bolt to 30 ft Ibs 41 Nm 14 Remove the lower ball joint pinch bolt D from the front bearing carrier 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 15 Using a soft face hammer tap on bearing carri
5. Safely support the box during the remainder of ag the removal process The box is not as stable with the shock removed 4 Remove the lower clip and pin attaching the shock to the vehicle frame if replacing the box shock m wa MEME n Box Shock Pin and y M Retaining Clip wa c L pa 6 With both hinge bolts removed lift the box from the frame Two people or an appropriate hoist may be needed to remove the box from the frame CAUTION Use caution when removing the box It is recommended to have two people carefully remove the box from the frame 5 18 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc Box Installation 1 If the shock was removed install the lower portion of the shock to the frame and secure it with the pin and clip Place the cargo box onto the frame Align the hinges of the box with the bracket on the frame Install the box hinge bolts on both sides Install the hinge bolt nuts on both sides and torque the nut to 30 ft Ibs 41 Nm With the hinge bolts installed attach the shock to the cargo box by inserting the pin and clip Connect tail light harness connector Lower the box and secure the latch BODY STEERING SUSPENSION 5 19 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION REAR STORAGE BOX 6X6 Exploded V
6. 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Seat Mounting Seat Belts XP HD 6x6 Bolt RH 3 Point 35 40 ft Ibs Seat Belt Le 47 54 Nm Bolt 35 40 ft Ibs Seat Back x 47 54 Nm T30 Screws 18 20 in Ibs 2 2 5 Nm LH 3 Point Seat Belt Seat Base Foil Heat Shield 2012 Only RH 3 Point Seat Belt Lap Belt Bolt Bolt 36 44 ft Ibs 2 49 60 Nm 36 44 ft Ibs Grommet Seat Support Bracket PII 2012 Only TEE Bolt 36 44 ft Ibs 49 60 Nm LH 3 Point Seat Belt Seat Base lt Frame Grommet in Bolt 36 44 ft Ibs 49 60 Nm 5 14 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Seat Mounting Seat Belts CREW Seat Back T30 Screws 18 20 in 1 5 i 2 2 5 Nm Bolt 35 40 ft Ibs 47 54 Nm Seat Base RH 3 Point Seat Belt x2 4 Foil Seat Support Bracket 2012 Only Bolt 35 40 ft Ibs 47 54 Nm e LH 3 Point B Seat Belt x2 Q Front Seat SN Lab Belt M Supports SENN x d B lt Heat Shield f9 N 2012 Only Grommet RH 3 Point Seat Belt x2 Bolt 36 44 ft Ibs 49 60 Nm 36 44 ft Ibs LH 3 Point Seat Belt x2 Bolt 36 44 ft Ibs Seat Base 49 60 Nm Frame 5 15 9923499 2011 2012 RANGER 800 Service Man
7. 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 3 Carefully remove the lower dash panel assembly from 7 Secure the steering wheel in the upward position to the vehicle Disconnectthe 12V outlets upon removal gain access to nuts A through the dash slot Reach I up under dash to gain access to shoulder bolts B 4 Locate power steering unit under the steering column Remove both nuts and pivot tube shoulder bolts A and B DO NOT REMOVE STEERING WHEEL 5 Disconnect the 2 electrical harnesses and remove the pinch bolt retaining the upper power steering shaft 8 Pull plastic dash up slightly and lift up on the steering to the power steering unit wheel pivot tube upper steering shaft assembly Remove assembly from vehicle and set in a suitable location CAUTION Striking the steering wheel or steering shaft can permanently damage the EPS unit and cause a Power Steering Fault 9 Remove the pinch bolt retaining the lower power steering shaft to the power steering unit 6 Remove the upper fastener retaining the steering tilt shock to the pivot tube and swing the shock down out of the way 5 30 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 10 Remove the 3 bolts retaining the power steering unit 2 Torque the mounting bolts to specification to the mounting bracket
8. 6X6 aas do kexedq eds tene Ld d edit ba 5 20 BODY COMPONENT REMOVAL ust ER ERE RR RU 5 21 LOWER SEAT BASE WHEEL WELL PANELS FRONT BUMPER FASCIA 5 21 FRONT FENDERS DASH GLOVE BOX STORAGE PANEL 5 22 REAR FENDERS FLOOR XP HD 6 6 5 23 MID REAR FENDERS FLOOR CREW 5 24 STEERING ASSEMBLY Ies re Pu pa mergea 5 25 STEERING WHEEL SHAFT REMOVAL NON EPS MODELS 5 26 STEERING SHAFT BEARING REPLACEMENT 5 27 POWER STEERING ASSEMBLY 5 28 STEERING WHEEL REMOVAL EPS MODELS nk eh erem 5 29 POWER STEERING UNIT 5 29 POWER STEERING UNIT INSTALLATION 5 31 FRONT AARMS wapu kutuy uuu RE SAN Rte Lade tog dece ds 5 32 BALL JOINT SERVICE s EROR EXC eme ee hg m Re heute 5 34 MIDZREAR AA ARMS dite de ae quM saa au om 5 36 REAR STABILIZER BAR LINKAGE i e RR RR RR 5 39 DEGAL HEPREAGEMIEDN T 5 dear E dri i Yu PU qur eese t dies 5 40 SHOCKS SPRINGS stake tbe DRE E Medo t e pp dedu 5 41 EXPLODED VIEW STANDARD WALKER 7 5 41 SHOCK REMOVAL INSTALLATION REPLACEMENT
9. Nm 8 Slide the clutch air intake box over the clutch intake hose Attach the clutch air intake box to the seat back using 4 14 self tapping screws Tighten fasteners to 18 20 in Ibs 2 2 25 Nm 9 Attach each headrest to the rear cab frame using four 1 4 self tapping fasteners Place washers between the fastener head and headrest as shown below Torque fasteners to 10 in Ibs 1 Nm 25 28 ft Ibs TT IDS 25 28 ft Ibs en 20 24 Nm 34 38 Nm 5 6 18 20 in Ibs 2 2 25 Nm 16 18 ft Ibs 20 24 Nm 18 20 Ibs 2 2 25 Nm 25 28 ft Ibs 34 38 Nm 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Exploded View Assembly CREW 1 Assemble RH LH front cab frame side hoops by sliding tube over the rear coupler Secure using 2 5 16 bolts and nuts Line up front side hoop couplers with front frame couplers and secure using 4 3 8 screws and nuts Leave all fasteners finger tight 2 Attach the front cab frame cross tube to the side hoops using 4 M10 screws Install the rear cab frame cross tube to the side hoops using 4 M10 screws Leave all fasteners finger tight Loosely install the rear cab frame K brace to the side hoops using 8 M8 screws and nuts Leave all fasteners finger tight Tighten 8 front and rear cab frame cross tube fasteners installed during Step 2 to 25 28 ft Ibs 34 38 Nm Tighten 2
10. Remove the 7 T27 Torx head screws retaining the glove box storage panel 3 Disconnect 12V power outlets and remove assembly 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Rear Fenders XP HD 6x6 1 Remove 11 T27 Torx head screws and 3 push rivets retaining the rear fender Fuel Cap RH Rear Fender Remove all T27 Torx head fasteners shown Remove all push rivets shown Floor XP HD 6x6 1 Remove 7 T27 Torx head screws retaining the rear floor Disconnect ECU harness and remove the rear floor Remove 8 T27 Torx head screws retaining the floor cover and remove the floor cover from the vehicle Main Floor Remove 4 nuts retaining throttle brake pedal mount NOTE If removing the RH side remove the fuel cap as well Reinstall fuel cap after fender removal 2 Repeat this procedure to remove other rear fender LH Rear Fender Loosen the glove box storage panel fasteners to access the screws retaining the upper portion of the main floor see Glove Box Storage Panel Remove 14 T27 Torx head screws retaining the main floor Remove 4 nuts retaining the brake throttle pedal mount and remove the main floor from the vehicle Rear Floor 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION NOTE If removing the rear RH side remov
11. and remove the power steering unit from the vehicle LO 20 24 ft Ibs 27 33 Nm Mounting Bracket Remove don t remove from frame Power Steering Unit Mounting Bolts 20 24 ft Ibs 27 33 Nm 3 Install pinch bolt retaining the lower power steering WARNING shaft to power steering unit Torque to specification Electronic Power Steering EPS units are not S T interchangeable between ATV and RANGER produci linas Lower Power Steering Shaft Pinch Bolt 15 19 ft Ibs 20 26 Nm Power Steering Unit Installation 4 Position steering wheel pivot tube upper steering Refer to the Power Steering Unit Removal procedure for shaft assembly into the proper mounting location Be detailed photos and illustrations during installation sure front wheels are pointing straight ahead and that the steering wheel is straight when installing the upper 1 Install power steering unit onto mount bracket and steering shaft onto the upper power steering stub align skip tooth spline on power steering stub shaft with the opening in the lower power steering shaft e Align skip tooth spline on power steering stub shaft with the opening in the upper power steering shaft Skip Tooth ill EA 1L Opening 4 ih Skip Tooth Opening 5 SS Shaft 4 5 31 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc B
12. down smoothly without interference If it does not disassemble and reassemble per this procedure 28 Secure the shock body in a vise by its lower mount 29 Pressurize the shock reservoir through the Schrader valve using the Gas Shock Recharging Kit PN 2200421 30 Continue filling until the shaft has fully extended and the reservoir pressure is at 200 psi Piggyback Shock Shown E L ZEE 4 Nitrogen Pressure 200 psi 1379 kPa A WARNING CHARGE THE SHOCK USING NITROGEN GAS ONLY DO NOT FILL WITH ANY OTHER GASES Doing so compromises the performance of the shock and may be EXTREMELY DANGEROUS 31 Reinstall the Schrader valve cap 32 Clean all oil residue from the shock and reservoir with solvent and dry with low pressure compressed air in a well ventilated area 33 Check shock for any leaks 5 51 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 34 Reinstall the compression spring and the spring retainer 35 Thread the spring preload adjuster down against the spring and set the preload to the specified measurement see Chapter 2 36 Set the compression adjuster knob to the recommended setting or the original setting upon removal see Chapter 2 37 Remove the shock from the vise 38 Reinstall spherical bearing O rings and polyurethane bushings NOTE After installation be sure to RIDE SLOW
13. is just below the surface of the oil 18 Hold the rod eyelet with one hand With other hand slide the bearing cap down the shaft until contact with the body is made Oil will overflow from around the bearing cap 19 Screw the bearing cap assembly into the shock body by hand holding the rod up so that the bearing cap is in contact with the bottom of the damping piston assembly Be careful not to cross thread the bearing assembly 20 Using a 1 open end wrench tighten the bearing cap 21 Using a 3 32 Allen wrench remove the IFP bleed Screw 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 22 Set the IFP depth to the specified length from the top of the reservoir Remote Reservoir b IFP Depth 3 375 0 13 1 In IFP Depth 3 375 85 725 mm 23 Using a long 3 32 Allen wrench install the IFP bleed Screw NOTE Apply grease to the end of the Allen wrench so the bleed screw sticks to it during installation 24 Pour the residual shock oil out of the reservoir into a proper disposal container 25 Install the reservoir cap Push down on the reservoir cap using even pressure until the retaining ring groove is exposed 26 Install the retaining ring and check to make sure retaining ring is seated properly 27 Push the shock rod assembly completely into the shock body It should go all the way
14. 0 38 4 Q3 R 43 n n o n a 14 MULA EA f 25 26 12 s e 6 3 Heo 9 22 NN B pli 8 a 32 29 SS o a d 37 zi 34 35 a 20005 91 L TL 3 4 gg 41 f 38 44 Ref Qty Description Ref Qty Description 1 1 Body Loop 24 1 Stud Clicker 2 1 Body Shock 25 1 O Ring 3 1 Seal Head 26 5 Detent Ball 4 1 Internal Bump Stop 27 2 Detent Spring 5 1 Bushing Shaft 28 1 Screw 10 32 6 1 O Ring 29 1 O Ring 7 1 Seal 30 1 Piston Reservoir 8 1 Wiper D Type 31 1 End Cap Reservoir 9 2 O Ring 32 2 O Ring 10 1 Shaft 33 1 Piston Wear Band Reservoir 11 1 Loop Shaft 34 1 O Ring 12 1 Washer 35 1 Screw 13 1 Piston 36 1 Valve Schrader 14 1 Nut Crimp 37 1 Bump Stop 15 2 Bearing Spherical 38 2 Clamp Reservoir 16 4 Snap Ring 39 1 Spacer Reservoir 17 1 Line 40 1 Screw 10 32 x 1 0 18 1 Hose Fitting 45 41 1 Spring Retainer 19 1 Body Reservoir 42 1 Preload Adjustment Ring 20 1 Housing Clicker 43 1 Spring 21 1 Piston Clicker 44 1 Snap Ring Reservoir 22 2 Bolt Clicker 45 1 Piston Wear Band Shock 23 1 Knob Clicker 5 43 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION WALKER EVANS SHOCK SERVICE Recommended Service Intervals Walker Evans Racing Shocks will perform the best if serviced at regular intervals Every ride Wash and dry
15. 025 1 30 x 008 1 20x 010 625 x 065 1 20 x 008 1 10 x 010 1 10 x 008 1 00 x 010 1 00 x 008 900 x 010 900 x 008 800 x 010 800 x 008 1 00 x 090 700 x 008 NOTE Valve shim stacks listed as 1 50 x 100 eyelet down threaded end up Piston Bleed Orifice 073 Piston Bleed Orifice 073 5 44 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Walker Evans Shock Rebuild Information When performing maintenance on Walker Evans shocks use the Gas Shock Recharging Kit PN 2200421 PART NUMBER DESCRIPTION as it contains the necessary valves pressure gauge and 2200421 Gas Shock Recharging Kit fittings to deflate and pressurize shocks Shock Shaft Seal Protector A WARNING CHAR 625 Diameter EEE 2870803 Shock Spring Pre Load Walker Evans shocks contain high pressure nitrogen Adjustment Tool gas Extreme caution must be used while handling and working with Walker Evans shocks and related high PS 45908 IFP Tool pressure service equipment The pressure must be released from the shock before disassembly It is strongly recommended you wear safety glasses and ear protection during these procedures Valve Shim Arrangement Shown below is an example of how valving stacks are arranged NOTE The rebound and compression valve stacks wi regardless of how the shock assembly is installed Special Tools
16. 5 16 fasteners installed during Step 1 to 16 18 ft lbs 20 24 Nm and 4 3 8 fasteners 25 28 ft Ibs 34 38 Nm Tighten the 8 M8 K brace fasteners installed during Step 3 to 16 18 ft Ibs 20 24 Nm Assemble the RH and LH rear cab frame side hoops by sliding the tube over the rear coupler Secure using 2 5 16 bolts and nuts Line up the front upper rear hoop couplers with the rear cab frame cross tube holes and secure using 2 M10 screws and nuts Leave all fasteners finger tight N m w 8 Installthe rear cab frame cross tube to the rear side hoops using 4 M10 screws Leave all fasteners finger tight 9 Loosely install the rear cab frame X brace to the rear side hoops using 8 M8 screws and nuts Leave all fasteners finger tight 10 Tighten 2 5 16 fasteners installed during Step 7 to 16 18 ft lbs 20 24 Nm and 4 M10 fasteners to 25 28 ft Ibs 34 38 Nm 11 Tighten the 4 rear cab frame cross tube fasteners installed during Step 8 to 25 28 ft Ibs 34 38 Nm 12 Tighten the 8 M8 X brace fasteners installed during Step 9 to 16 18 ft Ibs 20 24 Nm 13 Fasten the seat back to the rear cab frame X brace using 8 14 self tapping screws Tighten fasteners to 18 20 in Ibs 2 2 25 Nm Repeat this step to attach the front seat back to the mid cab frame K brace 14 Slide the clutch air intake box over the clutch intake hose Attach the clutch air intake box to the seat back using 4 14 self tapping scre
17. BODY STEERING SUSPENSION CHAPTER 5 BODY STEERING SUSPENSION TORQUE SPECIFICATIONS pri terco Cran bez s rad d a 5 2 SPECIAL TOOLS toc e NOR etnies ad e DEN ere 5 2 CHASSIS MAIN FRAME da sos og d act 5 8 CAB FRAME SEAT BACK HEADREST PVT AIR INTAKE BAFFLE 5 6 BODY EXPEODED VIEWS x sae ep b ant ee ER Edu 5 8 DASH INSTRUMENTS CONTROLS 2 942 gnictused Ino dedo sock e Rite 5 8 HOOD DASH FRONT FENDERS FRONT 5 9 2011 FLOOR REAR FENDERS HD 6 6 5 10 2012 FLOOR REAR FENDERS HD 6 6 5 11 2011 FLOOR REAR FENDERS CREW ied ure rae a e it ete 5 12 2012 FLOOR REAR FENDERS CREW eer ee tex Rey ke er eed 5 13 SEAT MOUNTING SEAT BELTS XP HD 6 6 5 14 SEAT MOUNTING SEAT BELTS CREW 5 15 REAR CARGO BOX cc ueg asado teat Rode ve Wnt eel EROR deo 5 16 CARGO BOX PANELS citi Et Ur DH Ra VAI Y 5 16 CARGO BOX TAILGATE BOX SUPPORT em en met e ER me 5 17 BOX REMOVAL TO kat bte sau de ays 5 18 pp LR ERA repasser a id 5 19 REAR STORAGE BOX
18. E Be sure the lower washers and spacers are still on the steering shaft 8 Apply Loctite 271 Red to the outer circumference of the new upper bearing race Slide the new upper bearing onto the steering shaft and press it into the pivot tube by hand NOTE Use care not to allow any of the Loctite to get in the bearing NOTE Bearings will be seated in the pivot housing upon tightening the steering wheel nut in step 14 9 10 11 12 14 15 16 Reinstall the upper washers and spacers in the order in which they were removed Install the steering wheel and hand tighten the nut Reinstall the steering shaft assembly in the vehicle Install the lower portion of the steering shaft onto the steering gear box assembly see Figure 5 16 Torque the lower pinch bolt to 30 ft Ibs 41 Nm Install the 2 fasteners that retain the pivot tube see Figure 5 17 Torque fasteners to 23 ft Ibs 31 Nm Install the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube see Figure 5 17 Torque fastener to 7 ft Ibs 10 Nm Be sure the front wheels are facing straight forward Remove the steering wheel and align as needed Torque the steering wheel nut to 28 ft Ibs 38 Nm Wipe the pivot tube clean of any excess Loctite Install steering wheel cap and field test steering operation 5 27 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polar
19. Hole 2 open before all gas pressure is released sS CAUTION 4 Make another indentation 1 in 25 mm from the bottom of the tube with a center punch To prevent personal injury wear safety glasses when center punching the shock absorber Use care not to puncture the shock absorber tube with the center punch 5 Drill a second hole in the shock absorber at the indentation using a 3 16 5 mm drill bit Oil will exhaust when the drill bit penetrates the shock absorber Use an oil pan and shop towels in order to 1 Make an indentation 2 in 50 mm from the top of the contain the escaping oil tube using a center punch 6 Remove shock absorber from the vise Hold the shock absorber horizontally with the holes down to drain the oil from the tube Move the shock rod in and out of the tube to completely drain the oil from the shock 2 Clamp the shock absorber in a vise horizontally with the shock absorber completely extended 7 Properly dispose the oil and discard the shock 5 42 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION WALKER EVANS SHOCK EXPLODED VIEW Walker Evans Compression Adjust Remote Reservoir Shock RANGER L E z fe 18 23 1 bi fo I 17 20 15 E Lj 2 OD 18 40 39 R 2
20. ILIZER BAR LINKAGE Removal Installation 1 Elevate and safely support vehicle with weight removed from the rear wheel s 2 Remove the retaining nut from the upper portion of the stabilizer bar linkage bushing on each side of the vehicle 3 Remove the two fasteners that secure the stabilizer bar to the main frame on each side Stabilizer Bar 4 Remove the stabilizer bar from the frame and inspect the stabilizer bar for straightness 5 Inspect the stabilizer bar bushings and replace if needed 6 Inspect the rubber bushings on the stabilizer linkage rod and replace if needed If replacing the stabilizer linkage remove the lower shock bolt from the upper A arm 7 Reverse this procedure for installation 8 Torque the stabilizer bar retaining bolts and upper rubber linkage bushing nuts to specification ey T Stabilizer Bar Retaining Bolts 17 ft Ibs 23 Nm e Upper Linkage Bushing 17 ft Ibs 23 Nm 9 Ifthe stabilizer linkage was removed torque the lower shock retaining bolt to specification Shock Mounting Bolts 30 ft Ibs 41 Nm Exploded View Carriage Bolts SN 7 Rubber lt N Aa Fos 17 ft Ibs A f Linkage 23 Nm O Bushing Bracket Bushings Upper A am 2 N 5 N Spacer gt lt KS 30 ft Ibs d 41 Nm 5 39 9923499 2011 2012 RANGER 800 Service Manual Copyrig
21. If needed use the spring compressor to compress the spring far enough to install the spring retainer IMPORTANT The spring retainer gap should be 180 from the end of the spring upon installation Preload Ring 5 Tighten spring preload adjustment ring Walker Evans or turn adjustment cam Standard to set preload distance noted in Step 1 see Chapter 2 for Retainer gap factory settings should be 180 Retainer from spring end 6 Reinstall shock onto vehicle and torque new fasteners to specification 5 41 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION SELF LEVELING SUSPENSION HD 3 Drill a hole in the shock absorber at the center punch using a 3 16 5 mm drill bit Gas or a gas oil mixture Nivomat Shock Operation will exhaust when the drill bit penetrates the shock absorber Use an oil pan and shop towels in order to The self leveling Nivomat shocks eliminate rear end contain the escaping oil squat when carrying heavy loads When the RANGER HD starts moving the Nivomat shocks start working automatically adjusting the box to near its unloaded height Automatically adjusts height Drill Hole 1 p No adjustments are necessary Nivomat Shock Disposal Replacement AX CAUTION Gas charged shock absorbers contain high SNN pressure gas Do not attempt to cut the shock BOTTOM 1 Drill
22. LY initially to ensure the shock and the vehicle s suspension is performing correctly 5 52 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc
23. ODY STEERING SUSPENSION 6 12 5 32 Loosely install pivot tube shoulder bolts B and nuts A Striking the steering wheel or steering shaft CAUTION can permanently damage the EPS unit and cause a Power Steering Fault Install upper shaft pinch bolt and torque to specification 1 Upper Power Steering Shaft Pinch Bolt 15 19 ft Ibs 20 26 Nm Verify thatthe pivot tube bushings are properly seated into the pivot tube Torque the pivot tube shoulder bolts and nuts to specification ey T Pivot Tube Shoulder Bolt 23 ft Ibs 31 Nm Install tilt shock and torque fastener to specification ey T Tilt Shock Fastener 12 ft Ibs 16 Nm Reconnect both electrical harnesses onto the power steering unit Be sure the connectors snap into place and the wires are routed correctly Reinstall the lower dash panel and glove box Be sure to reconnect the 12V outlets upon assembly Turn the key switch on and test EPS operation FRONT A ARMS Removal Replacement The following procedure details upper and lower A arm removal and replacement on one side of the vehicle 1 Elevate and safely support the front of the vehicle and remove the front wheel 2 Remove the lower shock fastener A from the upper A arm 3 Remove the brake line clamp from the A arm 4 Remove the upper ball joint pinch bolt B from the front bearing carrier
24. ON Installation 1 Place the A arm in the correct position for ball joint installation Face the A arm end flat on top of the driver Carefully drive the ball joint into place until the ball joint is properly seated Press into the A arm in this direction Place driver HERE to support A arm Upper A arm Shown 2 After the new ball joint is installed into the A arm install a NEW retaining ring Ball Joint Upper A arm Retaining Ring C3 3 Reinstall the A arm see FRONT A ARMS Removal Replacement 4 Repeat the ball joint service procedure for any additional A arm ball joint replacements 5 35 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION MID REAR A ARMS Removal Replacement The following procedure details upper and lower A arm removal and replacement on one side of the vehicle Repeat the following steps to remove the A arm s from the opposite side NOTE Use the exploded view in this section as a reference during the procedure 1 Elevate and safely support the rear of vehicle off the ground and remove the mid or rear wheel Upper A arm Removal 2 Removethe fastener retaining the lower portion of the shock and stabilizer linkage to the upper A arm 5 36 Remove the fastener attaching the upper A arm to the bearing carrier Remove the fasteners attaching the upper A arm to the frame a
25. SPENSION Front Fenders 1 Remove the lower T27 Torx head screws retaining the front fascia see Front Fascia T27 Screws see Front Fascia 2 Remove the 4 push rivets retaining the front fender and remove the fender from the vehicle 3 Repeat this procedure to remove other front fender Hood Dash 1 Remove front fascia see Front Fascia removal 2 Unlatch the hood and remove the 2 T27 Torx head screws to remove the hood assembly 3 Remove the front portion of the cab frame on each side to allow dash removal see Cab Frame Exploded View 4 Remove the 2 T25 Torx head screws retaining the front of the dash to the hood liner 5 22 5 Open the glove box and remove the 4 T20 Torx head screws from the dash Remove the front T20 Screws AA cab frame from each side of dash T25 Screws Fasteners and Rivets 6 Remove the 5 T25 Torx head screws retaining the rear portion of the dash 7 Remove the 8 fasteners from each side of the dash where it attaches to the front and rear fenders 8 Remove the rubber boots from around the parking brake and shift lever 9 Remove the 2 push rivets from dash panel see Dash Instruments Controls Unhook all electrical components to allow panel to be completely removed 10 Carefully remove the dash assembly from the vehicle Glove Box Storage Panel 1 Remove the hood dash see Hood Dash Remove 12V Outlets 2
26. bly _ _ Steering Shaft 2 Remove the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube Figure 5 17 Pivot Tube Remove the 2 fasteners that retain the pivot tube Remove the steering shaft pivot tube and steering wheel from the vehicle as an assembly Refer to steps 11 13 of the Steering Shaft Bearing Replacement procedure for installation 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Steering Shaft Bearing Replacement IMPORTANT Replacement pivot tube assembly comes with new upper and lower bearings installed Use this procedure if replacing just the bearings only 1 2 Perform the Steering Shaft Removal procedure Remove the steering wheel cap and retaining nut Press steering shaft out of the steering wheel and pivot tube Note the order and location of the washers and spacers between the steering wheel and pivot tube Drive the bearings out of the pivot tube using a drift punch Inspect the pivot tube bearing surfaces for signs of excessive wear or damage Apply Loctite 271 Red to the outer circumference of the new lower bearing race Slide the new lower bearing onto the steering shaft and install the steering shaft through the pivot tube NOTE Use care not to allow any of the Loctite to get in the bearing Pivot Tube Washer Thin Washers Bearing NOT
27. c BODY STEERING SUSPENSION BALL JOINT SERVICE Removal IMPORTANT Do not reuse a ball joint if it has been removed for any reason If removed it must be replaced Use this removal procedure only when replacing the ball joint 1 The A arm must be removed to perform this procedure see FRONT A ARMS Removal Replacement Ball Joint Upper A arm 2 Remove the retaining ring from the ball joint 3 Adriver must be used for the removal of the ball joint Use the dimensions below to fabricate or locate the correct size driver to use in the following process Driver Dimensions 1 375 in 3 49 cm 1 75 in 4 45 cm y Outside diameter of driver cannot be any larger than 1 75 in 4 45 cm Inside diameter cannot be any smaller than 1 375 in 3 49 cm Driver must be at least 3 in 7 62 cm tall 5 34 4 Use a press and correct size driver to remove the ball joint from the A arm Correct Driver Placement The driver must fit the inside diameter of the A arm end 1 Upper A arm Shown NOTE The driver must fit the ball joint housing in the A arm This will allow the ball joint to be properly pressed out of the A arm without damaging the A arm Press out of the A arm in this direction Upper A arm Shown Place driver HERE to support A arm 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSI
28. cal while rubbing lightly over the decal surface to eliminate any air bubbles during the application 5 40 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION SHOCKS SPRINGS Shock Removal Installation Exploded View Standard 1 Elevate the vehicle far enough off the ground to relieve the suspension load and support the A arm 2 Remove the upper and lower fasteners retaining the shock and remove the shock from the vehicle Discard nuts and replace with new upon installation 3 Reverse the procedure to reinstall the shock Torque new fasteners to specification Spring Retainer e T Shock Mounting Bolts 30 ft Ibs 41 Nm Shock Replacement 1 Remove shock and note the spring preload distance Adjusting Cam or setting see Chapter 2 for factory settings 2 Remove spring tension in order to remove retainer Standard Using a spring compressor compress shock spring far enough to remove spring retainer Walker Evans Loosen the preload adjustment 30 ft Ibs ring until the spring is loose If needed use a 41 Nm spring compressor to compress the spring far enough to remove the spring retainer Shock Spring Compressor Tool 30 ft Ibs Bushing 2870623 41 Nm 3 Remove spring and other components from existing shock and install components onto the new shock 4 Install the spring and spring retainer
29. e the fuel cap as well Reinstall fuel cap after fender removal 2 Repeatthis procedure to remove the other fenders Mid Rear Fenders CREW 1 Remove 19 T27 Torx head screws and 6 push rivets retaining the fenders RH Rear Fender Fuel Cap RH Mid Fender Remove all T27 Torx head fasteners shown Remove all push rivets shown d LH Rear Fender Floor CREW 3 Loosen the glove box storage panel fasteners to LL access the screws retaining the upper portion of the 1 Remove 7 T27 Torx head screws retaining either main floor see Glove Box Storage Panel rear floor Disconnect ECU harness if removing the Remove 14 T27 Torx head screws retaining the passenger rear floor main floor and remove 4 nuts retaining the brake 2 Remove 8 T27 Torx head screws retaining the floor throttle pedal mount Remove main floor from vehicle cover and remove the floor cover from the vehicle 5 See illustration if further disassembly is required Passenger Floor Passenger Front Floor Operator Rear Floor Floor Cover Main Floor Remove 4 nuts retaining throttle brake pedal mount Passenger Rear Floor 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION STEERING ASSEMBLY Exploded View Cap Steering Wheel 25 31 ft Ibs 34 42 Nm 5 Thick Washer Thin Washer P4 Bearing 23 ft Ibs 31 Nm 2 Pivot Tube
30. er to Exploded View loosen the lower A arm ball joint end while pushing downward on the lower A arm Completely remove the ball joint end from the bearing carrier AUN 16 Loosen and remove the lower A arm through bolt Pivot fasteners E and remove the lower A arm from the Tube vehicle Bushings 17 Examine A arm bushings and pivot tubes see Exploded View Replace if worn Discard hardware 18 If not replacing the A arm thoroughly clean the A arm y us and pivot tubes Kt 19 Install new ball joint into A arm Refer to Ball Joint Replacement section 20 Insert new A arm bushings and pivot tubes into new Tube Bearing I A arm Pinch Carrier 21 Install new lower A arm assembly onto vehicle frame Bolts Torque new bolts to 30 ft Ibs 41 Nm Pivot TAN 22 Insert lower A arm ball joint end into the bearing Nuts Tube carrier Install the lower ball joint pinch bolt D into the Bushings bearing carrier and torque bolt to 23 ft Ibs 31 Nm 2 430 it Ibs A WARNING zoftibs SO 41 Nm 41 Nm Upon A arm installation completion test vehicle at low speeds before putting into service Upper Lower A arm Bolt Torque 30 ft Ibs 41 Nm X e gt N 2 3 Ball Joint Pinch Bolt Torque 23 ft Ibs 31 Nm Lower A arm CV Shield 5 33 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales In
31. ets S D jo U Type SEU Speed Nut gt i Pa Hood Liner Screws Ud Model Year 2011 Shown 4 6 ft Ibs 6 8 Nm T27 Screws Fascia Screen 5 9 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 2011 Floor Rear Fenders XP HD 6x6 Rear RH Fender T27 INSTALLING NEW FOAM Make Rocker Panel Screws sure surface is clean and has 4 6 ft Ibs been flame treated Be sure to 6 8 Nm compress foam 5095 and Prid U Type make sure you don t trap any air crews 4 6 ft Ibs Speed Nut Foam 6 8 Nm Storage Container T27 Screws 4 6 ft Ibs 6 8 Nm Main Floor Push lt T27 Screws 4 6 ft Ibs Push 6 8 Nm Rivets Rear LH Fender Rocker Panel Wheel Well Panels Push Rivets Skid Plate Screws 6 8 ft Ibs 8 10 Nm 5 10 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 2012 Floor Rear Fenders XP HD 6x6 Rear RH Fender 27 Rocker Panel Screws 4 6 ft Ibs 6 8 Nm Bee U Type 4 6 ft Ibs X Speed Nut 6 8 Nm T Heat Shield NS Container U Type Speed Nut Main Push Floor Rivets q a Screws 4 6 ft Ibs 6 8 Nm Wheel Well Rear LH Fender Panels Rocker Panel Skid Plate Screws 6 8 ft Ibs 8 10 Nm 5 11 9923499 2011 2012 RANGER 800 Service Manual Cop
32. ht 2011 Polaris Sales Inc BODY STEERING SUSPENSION DECAL REPLACEMENT A WARNING The following procedure involves the use of an open flame Perform this procedure in a well ventilated area away from gasoline or other flammable materials Be sure the area to be flame treated is clean and free of gasoline or flammable residue A WARNING Do not flame treat components that are installed on the vehicle Remove the component from the vehicle before flame treating The side panels front and rear fender cabs are plastic polyethylene material Therefore they must be flame treated prior to installing a decal to ensure good adhesion A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged CAUTION Do not flame treat painted plastic components Painted plastic surfaces should only be wiped clean prior to decal adhesion To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy This should occur after just a few seconds of flame treating Do not hold the torch too close to the surface 2 3 inches from the flame tip is recommended Keep the torch moving to prevent damage 2 Apply the decal on one edge first Slowly lay down remainder of the de
33. iew Rivets Storage Box Base Rivets Mount Brackets 5 20 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION BODY COMPONENT REMOVAL Front Bumper 1 Remove the 2 T27 Torx head screws retaining the fascia screen and remove the screen Lower Seat Base 1 Lift up on the front of the seat base to disengage the seat from the rubber grommets Remove Screws Remove Rubber Grommets 2 Remove the 3 bolts from lower portion of bumper 2 Pull the seat base forward to disengage the rear tabs Remove the fasteners from each side of the upper and remove the seat base from the vehicle portion of the bumper 4 Carefully remove the bumper from the vehicle Wheel Well Panels 1 Using the multi function pliers remove the 6 push Front Fascia rivets from the LH panel and the 5 push rivets from 1 R the 2 T27 Torx head screws retaining the the RH panel ic d fascia screen and remove the screen Remove all T27 Torx head fasteners shown Be PUN botn pansis our mom ine wheel Wells 2 Remove the remaining T27 Torx head screws retaining the front fascia 3 Turn the headlight bulbs counter clockwise 90 and remove the bulbs from the head lamps 4 Carefully remove the fascia from the vehicle 5 21 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SU
34. in a vise using soft jaws to prevent cosmetic damage Back preload adjuster all the way down and carefully remove spring retainer and spring Spring Retainer Preload 7 Using a 1 open end wrench loosen and remove the bearing cap from the shock body 3 Remove the valve cap from the end of the reservoir 4 Carefully depressurize the shock 5 46 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 8 Slowly and remove the shock rod assembly from IMPORTANT Seal kits are available and should be the shock body installed at this time if seals or O rings are damaged or worn 12 Place the shock rod in a vise so the threaded part is facing up Using an 11 16 socket remove the nut retaining the valve stack and piston IMPORTANT Keep the rebound and compression valve stacks in the order they were removed If unsure of order refer to Shock Valving under the Shock Service Information provided earlier in this section Rebound side of piston NOTE Insert the IFP Tool PS 45908 and cycle the Internal Floating Piston IFP a few times to purge the shock oil from the line and reservoir 10 Remove the floating piston from the shock reservoir using the IFP Tool PS 45908 valve stac 13 Place the valve stack on a clean shop towel in order of removal 14 Inspect the valves for kinks waves pits or foreign mate
35. ipate Repeat the process until all the air has been removed 13 Pull the IFP up until its top is approximately 1 2 54 cm from the top of the reservoir and remove the IFP Tool Using a 3 32 Allen wrench install the IFP bleed Screw Shock Shown 4 IMPORTANT When the IFP Tool is removed the IFP must remain submerged in shock oil to prevent air from getting under the floating piston 14 Fill the shock body with oil approximately 1 4 below the threads 15 Apply a thin film of oil to the wear band on the damping piston Slowly insert the shock rod assembly into the body until the damping piston assembly is approximately 1 below the oil surface Move the rod up and down slowly over a range of about 1 until no air bubbles rise from the damping piston Be careful to keep the damping piston at least 1 4 below the surface of the oil during this process While holding the shock rod apply 2 3 sharp blows to the rod eyelet with a rubber mallet driving the piston down into the shock body This opens the valves on the damping piston You will see the released air bubbles come to the surface of the oil 5 50 16 Add oil to the body tube until the surface of the oil is at the top of the shock body threads Piggyback Shock Shown NOTE During installation some shock oil will over flow Wrap a shop cloth around the shock body to catch any oil overflow 17 Pull the damping piston up until it
36. is Sales Inc BODY STEERING SUSPENSION POWER STEERING ASSEMBLY EPS Exploded View To Pivot Tube Upper PS Shaft 15 19 ft Ibs 20 26 Nm Power Steering Unit Mounting Bracket 15 19 tt Ibs 20 26 Nm Se Lower 20 24 ft Ibs PS Shaft 27 33 Nm 30 ft Ibs 41 Nm Q Nut To Gear Box Asm 5 28 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Steering Wheel Removal EPS Models 5 Using alarge bronze drift and hammer strike steering shaft nut to pop the steering wheel off the shaft taper 1 Remove the upper steering shaft pivot tube and i Es steering wheel as an assembly before attempting to remove the steering wheel Refer to Power Steering Unit Removal EPS Models CAUTION Striking the steering wheel or steering shaft while installed in the vehicle can permanently damage the EPS unit and cause a Power Steering Fault 2 Remove the steering wheel cap 6 Once the steering wheel pops loose completely remove the nut and lift the steering wheel off the shaft Power Steering Unit Removal 1 Remove the cup holders from the upper dash panel Remove 3 Loosen the nut and back it half way off the steering shaft 2 Remove the fasteners retaining the lower dash panel and glove box 4 Place the assembly in a vise Disconnect 12V Outlets 5 29 9923499 2011
37. me Fascia Screen 28 32 ft Ibs 38 43 Nm 7 34 36 ft Ibs 46 49 Nm T27 Screws 13 15 ft Ibs 4 6 ft Ibs 17 20 Nm 6 8 Nm Bumper Screen LH Floor Support Bumper Guard Bracket 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION CAB FRAME SEAT BACK HEADREST PVT AIR INTAKE BAFFLE BOX Exploded View Assembly XP HD 6x6 1 Assemble RH LH cab frame side hoops by sliding tube over the rear coupler Secure using 2 5 16 bolts and nuts Line up front side hoop couplers with front frame couplers and secure using 4 3 8 screws and nuts Leave all fasteners finger tight 2 Attach the front cab frame cross tube to the side hoops using 4 M10 bolts Attach the rear cab frame cross tube to the side hoops using 4 M10 bolts Leave all fasteners finger tight 3 Loosely install the rear cab frame X brace to the side hoops using 8 M8 bolts and nuts Leave all fasteners finger tight 4 Tighten 8 front and rear cab frame cross tube fasteners installed during Step 2 to 25 28 ft Ibs 34 38 Nm 5 Tighten 2 5 16 fasteners installed during Step 1 to 16 18 ft lbs 20 24 Nm and 4 3 8 fasteners to 25 28 ft lbs 34 38 Nm 6 Tighten 8 M8 X brace fasteners installed during Step 3 to 16 18 ft lbs 20 24 Nm 7 Fasten the seat back to the X brace using 8 14 self tapping screws Tighten fasteners to 18 20 in lbs 2 2 25
38. nd remove the upper A arm from the vehicle Examine A arm and bearing carrier bushings and pivot tubes see Exploded View Replace if worn Discard hardware A WARNING The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation If not replacing the A arm thoroughly clean the a arm and pivot tubes Insert new A arm bushings and pivot tubes into the new A arm 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Lower A arm Removal Installation 8 Remove the fastener attaching the lower A armtothe 1 Install lower A arm assembly onto vehicle frame bearing carrier Torque new fasteners to 30 ft Ibs 41 Nm 2 Attach lower A arm to bearing carrier Torque new fastener to 30 ft Ibs 41 Nm 3 Route the brake line over the top of the lower A arm and secure it in the retainer 9 Remove the fasteners attaching the lower A arm to the frame and remove the lower A arm from the vehicle 4 Install upper A arm assembly onto vehicle frame Torque new fasteners to 30 ft Ibs 41 Nm 5 Attach upper A arm to bearing carrier Torque new fastener to 30 ft Ibs 41 Nm 6 Reinstall the lower portion of the shock and stabilizer linkage to the upper A arm Torque shock linkage fastener to 30 ft Ibs 41 Nm 7 I
39. nstall wheel and torque wheel nuts to specification see Chapter 2 10 Examine A arm and bearing carrier bushings and pivot tubes see Exploded View Replace if worn WARNING Discard hardware Upon A arm installation completion test vehicle at low speeds before putting into service A WARNING The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 11 If not replacing the A arm thoroughly clean the a arm and pivot tubes 12 Insert new A arm bushings and pivot tubes into the new A arm 5 37 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Exploded View 30 ft Ibs 41 Nm 30 ft Ibs 41 Nm lt Y Maie D 5 enar e G Bushings c e i T Bushings Upper A arm lt Shaft A N amp Bushings 3 30 ft Ibs 30 ft Ibs Bearing 8 Carrier DN lt 30 ft Ibs i B I 41 Nm MA 2 DA h A k 5 V AS 30 ft Ibs 5 Es ds 41 Nm Screws eG Bushings ow 8 7 9 A Bearing 30 ft Ibs A Snap Ring lbs 5 Bushings Shaft 5 38 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION REAR STAB
40. nto the reservoir body 2 Place the compression valve stack on the rod in the Tighten the valve stack fastener securely reverse order of disassembly 3 Place the valve piston on top of the compression stack Rebound side of piston Compression valve stack 5 48 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 6 Turn the compression adjuster knob counter 9 Using a 3 32 Allen wrench remove the IFP bleed clockwise soft until it stops so damping is in the full screw open position 10 Apply athin film of oil to the IFP O ring and wear band Insert the IFP into the reservoir until it is completely submerged Allow air to escape as you install the piston 7 Secure the shock body in a vise by its lower mount 8 Fillthe shock body and remote reservoir 1 2 full of the recommended gas shock oil Piggyback Shock Shown 11 Screw the IFP Tool PS 45908 onto the floating n piston Piggyback Shock Shown Recommended Shock Oil Racing Gas Shock Oil PN 2874522 Quart 5 Weight for Walker Evans Shocks e PS 45908 Piggyback Shock Shown 5 49 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 12 Slowly cycle the IFP up and down Be sure to bottom out the piston in the reservoir body Allow time for the bubbles to diss
41. per Lower A Arm Bolts 30 ft Ibs 41 Nm Rear Upper Lower A Arm Bolts 30 ft Ibs 41 Nm Front Ball Joint Pinch Bolts 23 ft Ibs 31 Nm Mid Rear Lower Bearing Carrier 30 ft Ibs 41 Nm Mid Rear Upper Bearing Carrier 30 ft Ibs 41 Nm Upper Lower Shock Bolts 30 ft Ibs 41 Nm Stabilizer Bar to Frame 17 ft lbs 23 Nm Stabilizer Bar Linkage Bushings 17 ft Ibs 23 Nm Front Wheel Hub Castle Nut 80 ft Ibs 108 Nm Mid Rear Wheel Hub Castle Nut 110 ft Ibs 150 Nm Wheel Nuts Cast Rims Wheel Nuts Steel Rims 30 ft Ibs 90 1 4 turn 35 ft lbs 47 Nm Outer Tie Rod to Bearing Carrier 40 ft Ibs 54 Nm Tie Rod End Jam Nut 12 14 ft lbs 17 19 Nm Seat Belt to Cab Frame 35 40 ft Ibs 47 54 Nm Seat Belt to Seat Base 36 44 ft Ibs 49 60 Nm Steering Wheel to Shaft 25 31 ft Ibs 34 42 Nm Upper Steering Shaft to U Joint Shaft 15 19 ft Ibs 20 26 Nm Lower Steering Shaft to Steering Box 30 ft Ibs 41 Nm Steering Box 17 ft lbs 23 Nm NOTE Refer to exploded views throughout this chapter for more torque specifications component identification and location of components 5 2 SPX Corp 1 800 328 6657 or http polaris spx com Multi Function Pliers Included in the tool kit this multi function pliers is designed to remove plastic push ri
42. rial 15 Inspect the piston wear band and replace if damaged or worn A PS 45908 Piggyback Shock Shown 11 Clean and inspect ALL parts and replace as needed 5 47 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 16 Using a 9 16 socket w extension remove the IMPORTANT If unsure of the valve stack order refer fastener retaining the clicker valve stack Place the to Shock Valving under the Shock Service valve stack on a clean shop towel in order of removal Information provided earlier in this section 4 Place a new lock nut onto the shock rod Torque the new lock nut to specification IMPORTANT Do not over torque the nut or damage to the valve stack can occur ey Lock Nut 14 ft Ibs 19 Nm Em stack j NOTE Make sure Top Out washers are orientated as shown IMPORTANT Keep the valve stack in the order it was removed If unsure of order refer to Shock Valving under the Shock Service Information provided earlier in this section Top Out 17 Inspect the valves for kinks waves pits or foreign 1 Washers material 18 Thoroughly clean all shock components and shock body prior to assembly Walker Evans Shock Assembly 1 Secure the shock rod in a vise with the threads of the rod facing up 5 Assemble the clicker valve stack on top of the fastener and install the assembly i
43. the vehicle and suspension Every 100 hours Visually inspect shock seals Every 500 hours or Annually Change shock oil and replace seals Front Shock Service Information Rear Shock Service Information Remote Reservoir IFP Depth 3 375 0 13 SHOCK DESIGN DETAILS Remote Reservoir IFP Depth 3 375 0 13 SHOCK DESIGN DETAILS Travel Stroke 5 985 Extended Length 16 385 IFP Location 3 375 85 725 mm Nitrogen Pressure 200 10 psi Gas Shock Oil 2874522 qt WE 5 wt SHOCK VALVING Travel Stroke 5 985 Extended Length 18 035 IFP Location 3 375 85 725 mm Nitrogen Pressure 200 10 psi Gas Shock Oil 2874522 qt WE 5 wt SHOCK VALVING COMPRESSION REBOUND CLICKER 1 50 x 008 1 50x 008 1 10x 025 1 45 x 008 1 45 008 1 10 x 012 1 30 x 008 1 30 x 008 1 00 x 025 1 20 x 008 1 20 x 008 625 x 065 1 10 x 008 1 10 x 008 1 00 x 008 1 00 x 008 900 x 008 900 x 008 800 x 008 800 x 008 700 x 008 700 x 008 750 x 065 750 x 065 1 50 100 NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a vise eyelet down threaded end up COMPRESSION REBOUND CLICKER 1 55 x 008 1 50x 012 1 10x 025 1 50 x 008 1 45 x 012 1 10x 012 1 45 x 008 1 30 x 010 1 00 x
44. ual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION REAR CARGO BOX Cargo Box Panels RH Box Panel Tailgate Support Latch uw aN T30 Screws CS SN NY NO Cargo Box T20 Screw Front Box Panel LH Box Panel Foil 2012 Only 5 16 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Cargo Box Tailgate Box Support Outer Panel Tailgate Cap Tailgate end I Bracket Tailgate Cable T30 Screws Tailgate Cable T27 Screws p T27 Screw Tailgate Tube T30 Screws Box Support Box Latch Heat Shield EM ASS 4 B s Bumper Springs Bushings P P 5 Shock Pins EX N 2 PS z Clip Screw 2 5 17 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Box Removal 5 Remove nut A and bolt B that secure the box frame on both pivot points 1 Liftthe cargo box into the dump position 2 Disconnect the rear wire harness attached to the tail lights 3 Remove the upper clip and pin attaching the shock to the cargo box Box Shock Pin and Retaining Clip E CAUTION Safely support the box during the remainder of the removal process The box is not as stable with the hinge pins removed CAUTION Slide Bolt Out
45. vets and install body components Push Rivet 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION CHASSIS MAIN FRAME Exploded View XP HD Seat Base Dash Support RH Floor Support Main Frame Cap 28 32 ft Ibs Fascia 38 43 Nm Screen 28 32 ft Ibs 38 43 Nm 9 T27 Screws 4 6 ft Ibs 6 8 13 15 ft Ibs UMP er 17 20 Nm Screen Bumper Guard Bracket Bumper LH Floor Support 5 3 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Exploded View CREW Rear Seat Base Front Seat Base Rear Frame Dash Support 38 40 ft Ibs 52 54 Nm 28 32 ft Ibs k ACT 38 43 Nm Frames 38 40 ft Ibs 52 54 Nm RH Floor Support Cap 38 40 ft Ibs 52 54 Nm Fascia Screen U lt 28 32 ft Ibs 38 43 Nm ss 38 40 ft Ibs 52 54 Nm T27 Screws 13 15 ft Ibs 4 6 ft Ibs 17 20 Nm 6 8 Nm LH Floor Support Bumper Guard Bracket Bumper 5 4 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Exploded View 6x6 Seat Base Dash Support ROPS Bracket 34 36 ft Ibs 46 49 Nm RH Floor Support 28 32 ft lbs 8 43 N 3 m 34 36 ft Ibs 46 49 NM Main Fra
46. ws Tighten fasteners to 18 20 in Ibs 2 2 25 Nm 15 Attach the headrest to the rear cab frame using 4 1 4 self tapping fasteners Place washers between the fastener head and headrest as shown below Torque fasteners to 10 in Ibs 25 28 ft Ibs 25 28 ft Ibs 25 28 ft Ibs TNT 34 38 Nm 34 38 Nm 34 38 Nm O 16 18 ft Ibs EH 20 24 Nm pe f 18 20 in Ibs 2225Nm 25 28 ft Ibs 34 38 Nm 16 18 ft Ibs 2 20 24 Nm 16 18 ft Ibs 77 R 20 24 Nm A 18 20 in Ibs LJ DY He 2 225 Nm 16 18 ft Ibs 20 24 Nm 5 7 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION BODY EXPLODED VIEWS Dash Instruments Controls A Instrument Cluster Speedo B Headlight Switch C AWD 2WD TURF Switch D 12 Volt Accessory Receptacle 2 E Rubber Mount F Key Switch G Grommet H Push Rivet I Dash Plug J Dash Panel 5 8 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION Hood Dash Front Fenders Front Fascia T27 Screws 4 6 ft Ibs 6 8 Nm Hood Front RH Fender Screws Push Rivets Hinge 4 6 ft Ibs 6 8 Nm Cup Holder T27 Screw 4 6 ft Ibs 6 8 Nm Front Fascia Screws 4 6 ft lbs Front LH Fender y T27 Ls Screws Push Riv
47. yright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 2011 Floor Rear Fenders CREW Plugs Storage Container Underseat Storage box Screws 4 6 ft lbs U Type Rear Lower Floor RH Fenders Rocker Panels INSTALLING NEW FOAM Make sure surface is clean and has been flame treated Be sure to compress foam gt 50 and make sure you don t trap any air U Type et Speed Nut Rivets 27 Rear LH Fender Screws Rocker Panel 4 6 ft Ibs 6 8 Nm Wheel Well Front LH Fender Panels Rocker Panel Skid Plates Screws 6 8 ft Ibs 8 10 Nm 5 1 2 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BODY STEERING SUSPENSION 2012 Floor Rear Fenders CREW Plugs Storage Pu NN 225 Container lt Heat Shield Underseat Storage box l Y SSS U Type M fe SS PRN Speed Nut Cover R 225 A h Tees lt S gt d in Retainer Rear Jc Floor S S Sm 3 Main ir tr ADSL 7 EA Rear Floor NL 7 Floor Rear Lower Floor U Type RH Fenders Rocker Panels Speed Nut _ T27 Screws 4 6 ft Ibs 6 8 Nm gt T27 Screws Push U Type Speed Nut Rear LH Fender Screws Rocker Panel 4 6 ft lbs 6 8 Nm Front LH Fender Deflector Rocker Panel Wheel Well Panels Skid Plates Screws 6 8 ft Ibs 8 10 Nm 5 13 9923499
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