CHAPTER 3 ENGINE

ENGINECylinder / Piston - Engine SpecificationsMain Components: Cylinder / Piston / Connecting RodCylinderRGR800-11,XP (1204172)RGR800-12 (1204397); RGR800-12LK (1204486)Cylinder - Surface warp limit(mating with cylinder head)0.004" (0.10 mm)Cylinder Bore - Standard3.1495" (80 mm)Cylinder Taper Limit0.00031" (0.008 mm)Cylinder Out of Round Limit0.00030" (0.0075 mm)Cylinder to Piston Clearance.0015" .00059" (.040 .015 mm)Lifter Outer Diameter Standard0.84245" 0.00025" (21.39 8 0.00635 mm)Lifter Block Bore0.8438" 0.00062" (21.4322 0.0157 mm)Piston - Standard3.14803" .00028" (79.960 .007 mm)Piston Standard Inner Diameter of Piston Pin Bore0.70902" .00012" (18.009 0.003 mm)Piston Pin Outer Diameter0.70866" - 0.70846" (18 - 17.995 mm)Piston Pin - Standard Clearance - Piston Pin toPin Bore0.00047" 0.00024" (0.012 0.006 mm)Piston Pin - Degree of FitPiston pin must be push fit (by hand) at 68 F (20 C)3LifterPistonPiston PinPiston / Connecting Rod / Crankshaft - Engine SpecificationsMain Components: Piston / Connecting RodInstalledGapRGR800-11,XP (1204172)RGR800-12 (1204397); RGR800-12LK (1204486)Top Ring - Standard0.0059 - 0.0138" (0.15 - 0.35 mm)Top Ring - Limit 15% LeakdownSecond Ring - Standard0.0098 - 0.0197" (0.25 - 0.50 mm)Second Ring - Limit 15% LeakdownOil Ring - Standard0.0197 0.0098" (0.50 0.25 mm)Oil Ring - Limit 15% LeakdownTop Ring - Standard0.0024" 0.0008" (0.060 0.020 mm)Top Ring - Limit 15% LeakdownSecond Ring - Standard0.0028" 0.0008" (0.070 0.020 mm)Second Ring - Limit 15% LeakdownPiston RingRing toGrooveClearanceConnecting Rod Small End I.D.Connecting Rod Small EndRadial ClearanceConnecting RodCrankshaft0.7096"- 0.70846" (18 - 17.995 mm)0.00098" 0.00039" (0.025 0.010 mm)Connecting Rod Big EndSide Clearance0.01181" 0.00591" (0.30 0.15 mm)Connecting Rod Big EndRadial Clearance0.0015" 0.0006" (0.038 0.015 mm)Crankshaft Runout Limit0.00236" (0.060 mm)3.99923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ENGINESpecial ToolsPart NumberTool DescriptionPU-50105OIL FILTER WRENCHPU-45257VALVE SPRING COMPRESSORPU-45652VALVE PRESSURE HOSE2871043FLYWHEEL PULLER2870390PISTON SUPPORT BLOCKPU-45497-1CAM GEAR SPRING INSTALLATION KITPU-45497-2CAM GEAR TOOTH ALIGNMENT TOOLPU-45498CAM SPANNER WRENCHPU-45838GEAR HOLDERPA-44995WATER PUMP MECHANICAL SEAL INSTALLERPU-45543UNIVERSAL DRIVER HANDLEPA-45483MAIN SEAL INSTALLERPU-45658CRANKSHAFT MAIN SEAL SAVERPA-45401WATER PUMP SEAL SAVER2870975MITY VAC PRESSURE TEST TOOLPU-45778OIL SYSTEM PRIMING TOOLSPX Corporation: 1-800-328-6657 or http://polaris.spx.com/3.109923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ENGINEENGINE COOLING SYSTEMCooling System Pressure TestCooling System Specifications1. Open the front hood.ConditionWARNINGCoolant Temperature F ( C)Room Temperature68 F (20 C)Thermostat Closed175 F (79 C)Thermostat Open180 F (82 C)Fan Off194 F (90 C)Thermostat Full Open Lift202 F (94 C)Fan On205 F (96 C)Engine TemperatureOverheat IndicatorMoving Vehicle: 235 F (113 C)Engine Protection Ignition MisfireMoving Vehicle: 239 F (115 C)Engine ProtectionShutdownMoving Vehicle: 257 F (125 C)Idle Vehicle:Idle Vehicle:Idle Vehicle:ItemNever remove radiator cap when engine iswarm or hot. The cooling system is underpressure and serious burns may result.Allow the engine to cool before servicing.2. Remove the pressure cap from the radiator andpressure test the cooling system using a commerciallyavailable tester.241 F (116 C)244 F (118 C)262 F (128 C)SpecificationXP / HD / 6X6 3.25 qts. (3.1 L)Cooling System CapacityCREWPressure Cap Relief6.4 qts. (6 L)13 PSIPolaris Premium Antifreeze2871534 - Quart2871323 - GallonRecommended CoolantUse only high quality antifreeze/coolant mixed withdistilled water in a 50/50 or 60/40 ratio, depending onfreeze protection required in your area.IMPORTANT: Using tap water in the cooling systemwill lead to a buildup of deposits which may restrictcoolant flow and reduce heat dissipation, resulting inpossible engine damage. Polaris Premium 60/40Antifreeze/Coolant is recommended for use.3. The system must maintain 10 psi for five minutes orlonger. If pressure loss is evident within five minutes,check the radiator, all cooling system hoses, clampsand water pump seal for leakage.Radiator Cap Pressure Test1. Open the front hood (see Warning under “CoolingSystem Pressure Test”).2. Remove radiator pressure cap and test using apressure cap tester (commercially available).3. The radiator cap relief pressure is 13 psi. Replace capif it does not meet this specification.3.119923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.3

ENGINECooling System Bleeding ProcedureWARNINGAlways wear safety glasses and proper shopclothing when performing the procedures in thismanual. Failing to do so may lead to possibleinjury or death.CAUTION4. Start the engine and allow it to idle for 5-10 minutesor until the thermostat opens and allows coolant toflow through the system.5. Squeeze coolant hoses by hand to help purge systemof air.6. Slightly loosen the bleed screw (C) on the cylinderhead to let air escape. If no air is present, a steadystream of coolant will stream out. If air is present, thescrew will bubble and sputter as the air escapes.Use caution when performing these procedures.Coolant may be hot and may causesevere injury or burns.NOTE: If the coolant level is LOW in the radiator, orif there are leaks in the system, the coolant systemwill not draw coolant from the recovery bottle.NOTE: Use this procedure when overheating occursand no apparent leaks in the cooling system arefound.1. Place the vehicle in Neutral and set the parkingbrake.CSpark PlugTop LH Sideof Cylinder Head7. Tighten the bleed screw to specification and properlyinstall the radiator pressure cap.CAUTIONBe sure the engine has cooled and there is nopressure built up in the cooling system beforeremoving the radiator cap. The coolant may behot and could cause severe injury or burns.2. Remove radiator cap and top off coolant. TCoolant Bleed Screw:70 10 in. lbs. (8 1.13 Nm)8. Add Polaris Premium Antifreeze to the radiator if thelevel goes down.3. Remove recovery bottle cap and fill to the “MAX” line.WARNINGRecovery BottleRadiator CapBe sure to install the pressure cap beforeshutting off the engine.Coolant may spit out of the radiator.9. Stop the engine and allow it to cool. Top off theradiator with coolant. If you hear or see a “glug” at thefiller neck or the coolant level drops indicating thatcoolant has been pulled into the system, fill theradiator first before filling the recovery bottle.10. Any air remaining in the system should continue tobleed out through the recovery bottle.11. Repeat this procedure if you are still having difficultybleeding the system.3.129923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ENGINECooling System Exploded View3Coolant Flow DiagramFiller NeckEngineWater PumpEngineCylinder Head BypassRecovery BottleRadiatorEngineThermostat Housing3.139923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ENGINEGENERAL ENGINE SERVICEEngine Lubrication SpecificationsEngine Intake Restrictor OrificeSome RANGER 800 models are equipped with an intakerestrictor orifice in order to meet vehicle class regulations.This restrictor MUST NOT be removed for any reason. Capacity: Approximately 2 U.S. Quarts (1.9 l)Oil Type: Polaris PS-4 PLUS SyntheticFilter Wrench: PU-50105 - 2.5” (64 mm)- Oil Pressure Specification 27-35 PSI @ 6000 RPM, PS-4 PLUS SyntheticEngine at operating temperatureOil Pressure Test1. Remove blindcrankcase.IMPORTANT: Removal of the intake restrictor orificewill void the warranty of any RANGER HD, CREW or6x6 model.plug/senderfromleftsideof2. Insert a 1/8 NPT oil pressure gauge adaptor into thecrankcase and attach the gauge.3. Start engine and allow it to reach operatingtemperature, while monitoring the gauge.NOTE: Use only Polaris PS-4 PLUS Synthetic 4Cycle Engine Oil.Accessible ComponentsThe following components can be serviced or removedwith the engine installed: Flywheel Alternator (Stator)Oil Pressure at 6000 RPM (Engine Hot):Minimum: 27 PSIStandard: 31 PSIMaximum: 35 PSI Starter Motor/Drive Cylinder Head Cylinder Piston / Rings Camshaft Rocker Arms Oil pump / Water Pump / Oil Pump Drive Gear Gear Train ComponentsThe following components require engine removal forservice: Counterbalance Shaft or Bearings Connecting Rod Crankshaft Crankshaft Main Bearings Crankcase3.149923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ENGINEOil Flow ChartThis chart describes the flow of oil through the 800 engine. Beginning in the crankcase sump, the oil is drawn throughan oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, abypass valve contained in the filter allows oil to bypass the filter element. At this point, the oil is supplied to the main oilgalley through a crankcase passage. Oil is then diverted three ways from the main oil galley, with the first path enteringthe camshaft bores, onto the rear balance shaft journal and then draining back into the crankcase sump. The secondoil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump. The third oil path flowsthrough a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto thecrankcase sump.33.159923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ENGINEEngine RemovalIMPORTANT: Some engine repair procedures can beperformed without removing the engine. Refer to“Accessible Components” for further information.9. Remove the (4) exhaust pipe bolts and remove thepipe.NOTE: Upon engine removal, use a mechanical liftor have an assistant help remove the engine fromthe vehicle to prevent personal injury or damage tovehicle components.WARNINGAlways wear safety glasses and proper shopclothing when performing the procedures in thismanual. Failing to do so may lead topossible injury or death.10. Place a small catch-container under the fuel rail andcarefully disconnect the fuel line from the rail.1. Clean your work area.Fuel line Connector2. Thoroughly clean the engine and chassis.3. Open the hood and disconnect battery (-) negativecable.4. Drain the engine oil and engine coolant (see Chapter2).NOTE: Drain and dispose of the fluids properly.5. Remove the lower seat base and storage container.6. Remove the rear floor to better access the engine.The floor can be removed by removing (3) fenderscrews (3) rear floor screws as shown below.Breather Hose11. Remove the breather hose from the valve cover.12. Disconnect the T-MAP, IAC and TPS sensorconnectors from throttle body.7. Disconnect the ECU harness to allow the floor to beremoved from the vehicle.8. Remove the springs from exhaust pipe.3.169923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ENGINE13. Loosen the clamps that secure the throttle body to theair intake track. Remove the throttle body and supportit out of the way. Do not allow the throttle body to hangfrom the throttle cable.17. Remove the spark plug high tension leads.14. Insert a shop towel into the engine intake to preventdirt from entering the intake port.15. Disconnect the fuel injectors at the wire harnessconnectors as shown below.3IMPORTANT: Mark or note which ignition coil wiregoes to which cylinder and ignition coil post. Theengine will misfire if the spark plug wires are installedincorrectly. The spark plug wires are marked with PTOand MAG from the factory and should be installed tothe corresponding cylinder and ignition coil post.16. Mark the fuel injector harnesses to identify MAG andPTO harness connections to aid during reassembly.Disconnect the fuel injector harnesses.NOTE: The fuel injector harness connector andlocking spring is bonded to the fuel injectors with anepoxy mix. DO NOT attempt to disconnect theconnector from the fuel injectors. Damage will occurto the injector and/or harness if attempting toseparate at that location. Separate the fuel injectorfrom the vehicle by disconnecting at the end of theharness as shown.FuelInjector18. Disconnect the stator harness and crankshaft positionsensor (CPS) harness or remove the (CPS) from themagneto cover.CPSStatorHarnessDisconnect Here19. Disconnect cam phase sensor (near oil filter).HarnessDO NOTDisconnect HereIMPORTANT: Take note of PTO and MAG fuel injectorharness connectors before disconnecting them. Theharnesses are different and can not be connectedincorrectly (PTO - Gray; MAG - Black).Cam PhaseConnector3.179923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ENGINE20. Remove the outer clutch cover with PVT outlet duct,drive belt, drive clutch, driven clutch and inner clutchcover (see Chapter 6 “Clutching”).25. Remove engine mount fasteners as shown below.21. Remove the rear PVT inlet hose from the enginecrankcase.22. Disconnect the engine coolant temperature (ECT)sensor harness and the bypass coolant hose from theleft side of the cylinder head.ECTConnectorCoolantBypass23. Remove the coolant hoses from the engine. Properlydispose of any coolant drained from the engine orhoses.24. Remove the battery cables from the starter motor.When removing starter cables, note and mark groundcable and positive ( ) cable mounting angle andlocations.26. Carefully remove the engine through the top of theseat base frame. Lift the engine forward to free it fromthe rear mount and then lift the engine out from thevehicle.NOTE: Rotating the engine to the left 90 degrees(valve cover facing left) may ease engine removal.NOTE: Use caution when lifting the engine out offrame. Use an engine lift or other means, if theengine appears too heavy to be lifted manually.3.189923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ENGINEEngine Installation NotesAfter the engine is installed in the frame, review thischecklist and perform all steps that apply:General Items1. Install previously removed components using newgaskets, seals, and fasteners where applicable.NOTE: Properly route all electrical harnesses andre-attach any fasteners or protective tubing. Checkfor any possible rubbing points of electrical wires.2. Perform regular checks on fluid levels, controls, andall other areas of the vehicle as outlined in the dailypre-ride inspection checklist (refer to Chapter 2“Maintenance”).PVT System1. Adjust clutch center distance, clutch offset and/orclutch alignment (see Chapter 6 “Clutching”).Engine Break-In PeriodThe break-in period for a Polaris RANGER engine isdefined as the first 25 hours of operation, or the time ittakes to use 2 full tanks of gasoline. No single action onyour part is as important as a proper break-in period.Careful treatment of a new engine will result in moreefficient performance and longer life for the engine.Perform the following procedures carefully:CAUTIONUse only Polaris PS-4 PLUS Synthetic 4-Cycleengine oil or an equivalent. Never substitute ormix oil brands. Serious engine damage andvoiding of warranty can result.Do not operate at full throttle or high speeds forextended periods during the first three hours ofuse. Excessive heat can build up and causedamage to close fitted engine parts.1. Fill fuel tank with unleaded or leaded fuel which hasa minimum pump octane number of 87 (R M)/2.2. Clean clutch sheaves thoroughly and inspect inlet andoutlet ducts for proper routing and sealing (seeChapter 6).2. Check oil level indicated on dipstick. Add oil ifnecessary (Refer to Chapter 2, “Engine Oil Level” ).Transmission3. Drive slowly at first to gradually bring engine up tooperating temperature.1. Inspect transmission operation and adjust the shiftcable if necessary. Refer to Chapter 2 and Chapter 8.Exhaust1. Replace exhaust gaskets. Seal connections with hightemp silicone sealant.2. Check to be sure all springs are in good condition.Bleed Cooling System4. Vary throttle positions. Do not operate at sustainedidle or sustained high speed.5. Perform regular checks on fluid levels, controls and allimportant bolt torques.6. Pull only light loads during initial break-in.7. Change oil and oil filter after break-in period at 25hours.NOTE: Follow coolant bleeding procedure outlinedearlier in this chapter3.199923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.3

ENGINEENGINE DISASSEMBLY AND INSPECTIONCylinder Head Assembly Exploded ViewHead BoltsValvesRocker ArmsRetainer Locks (keepers)Push RodsSpring RetainersSpringsValve Seals (2)Valve Spring Seats (2)Coolant BleederCylinder HeadHydraulic Lifters3.209923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ENGINERocker Arms5. If the push rod (A) is visibly bent, it should be replaced.1. Remove the valve cover.A2. Mark or tag rocker arms in order of disassembly tokeep them in order for reassembly.3Cylinder Head Removal3. Inspect the wear pad at the valve end of the rockerarm for indications of scuffing or abnormal wear. If thepad is grooved, replace the rocker arm.NOTE: Do not attempt to true this surface bygrinding.4. Check the rocker arm pad and fulcrum seat forexcessive wear, cracks, nicks or burrs.Push Rods1. Clean push rods (A) in a suitable solvent. Blow drypush rods with compressed air.NOTE: The cargo box assembly and the upper framebolt-in brace must be removed to allow enoughclearance to remove all the cylinder head bolts.Refer to Chapter 5 for removal procedures.1. Loosen the six cylinder head bolts (A) evenly 1/8 turneach in a criss-cross pattern until loose.2. Remove bolts (A) and tap cylinder head (B) lightly witha soft face hammer until loose. CAUTION: Tap onlyin reinforced areas or on thick parts of cylinder headcasting to avoid damaging the head or cylinder.3. Remove cylinder head (B) and head gasket (C) fromthe cylinder (D).2. Use compressed air to confirm the oil passage is clearin the center of the push rod.WARNINGAlways wear safety glasses when working withcompressed air to prevent personal injury.3. Check the ends of the push rods (A) for nicks,grooves, roughness or excessive wear.ABC4. The push rods (A) can be visually checked forstraightness while they are installed in the engine byrotating them with the valve closed. Push rods canalso be checked with a dial indicator or rolled acrossa flat surface to check for straightness.D3.219923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ENGINECylinder Head InspectionValve Seal / Spring Service (On Engine)Thoroughly clean cylinder head surface to remove alltraces of gasket material and carbon.NOTE: The following procedure is only for servicingthe top end of the valve train when replacing valvesprings or replacing valve seals.CAUTIONUse care not to damage sealing surface.In some cases the valve train can be serviced while thecylinder head is still on the engine. Keep all parts in orderwith respect to their location in the cylinder head.WARNINGCylinder Head Warp1. Lay a straight edge (A) across the surface of thecylinder head (B) at several different points andmeasure warp by inserting a feeler gauge betweenthe straight edge and the cylinder head surface. Ifwarp exceeds the ser

Cylinder / Piston - Engine Specifications Main Components: Cylinder / Piston / Connecting Rod RGR800-11,XP (1204172) RGR800-12 (1204397); RGR800-12LK (1204486) Cylinder Cylinder - Surface warp limit (mating with cylinder head) 0.004" (0.10 mm) Cylinder Bore - Standard 3.1495" (80 mm)