CHAPTER 3 ENGINE - Polaris ATV | Alternative …

1 3 ENGINE3 ENGINE9923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales SPECIFICATIONS .. PUMP / GEARS / ENGINE COVER.. COVER / STARTER / WATER PUMP / LUBRICATION SYSTEM .. / CYLINDER HEAD / PISTON .. EFI SENSORS / VALVE COVER / GENERAL COMPONENTS .. TORQUE SPECIFICATIONS.. EFI ENGINE SERVICE SPECIFICATIONS.. TOOLS .. COOLING SYSTEM .. SYSTEM SPECIFICATIONS / PRESSURE TEST .. CAP PRESSURE TEST .. SYSTEM BLEEDING PROCEDURE .. SYSTEM EXPLODED VIEW.

2 ENGINE SERVICE .. INTAKE RESTRICTOR ORIFICE .. COMPONENTS.. LUBRICATION SPECIFICATIONS / OIL PRESSURE TEST .. FLOW CHART .. REMOVAL .. INSTALLATION NOTES .. DISASSEMBLY AND INSPECTION .. HEAD ASSEMBLY EXPLODED VIEW .. ARMS / PUSH RODS.. HEAD REMOVAL .. HEAD INSPECTION / WARP .. SEAL / SPRING SERVICE (ON ENGINE ) .. HEAD DISASSEMBLY .. INSPECTION .. CHAMBER.. SEAT RECONDITIONING .. HEAD REASSEMBLY .. SEALING TEST .. REMOVAL .. LIFTER REMOVAL / INSPECTION.

3 REMOVAL .. INSPECTION.. HONE SELECTION AND HONING PROCEDURE .. TO DEGLAZE / CLEANING THE CYLINDER AFTER HONING.. CLEARANCE .. / ROD INSPECTION.. RING INSTALLED GAP .. DRIVE BENDIX REMOVAL / INSPECTION .. / STATOR REMOVAL / INSPECTION .. CRANKCASE DISASSEMBLY / INSPECTION .. INSPECTION .. REASSEMBLY .. REASSEMBLY .. / STATOR INSTALLATION .. HEAD REASSEMBLY .. PUMP PRIMING .. BREAK-IN .. - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales SPECIFICATIONSC rankcase Exploded - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Pump / Gears / ENGINE Cover Exploded - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Cover / Starter / Water Pump / Lubrication System Exploded - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales / Cylinder Head / Piston Exploded - 2011 / 2012 RANGER 800 Service

4 Manual Copyright 2011 Polaris Sales EFI Sensors / Valve Cover / General Components Exploded ViewNOTE: See CHAPTER 4 for more information on the EFI System - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Torque SpecificationsNOTE: * See exploded views for notes or torque lbs. (Nm)ft. lbs. (Nm)Camshaft Gear8 mm-22 2 (30 3)Camshaft Phase Sensor Bolt6 mm50 5 ( )-Camshaft Thrust Plate6 mm115 12 (13 ) 1 (13 )Coolant Bleed Screw6 mm70 10 ( )-Coolant Bypass Hose Fitting3/8 NPT115 (13 ) 1 (13 )Counterbalance Gear8 mm-22 2 (30 3)Crankcase Bolts8 mm-* 22 2 (30 3)Crankcase Breather5 mm84 8 ( )-Cylinder Head Bolts 11 mm-* 35 4 ( )Exhaust Manifold8 mm216 24 ( )18 2 ( )Flywheel14 mm-65 7 (88 )

5 Injector Rail8 mm216 24 ( )18 2 ( )Magneto Cover6 mm* 96 3 ( )-Oil Baffle Weldment5 mm60 6 ( )-Oil Drain Bolt (Crankcase)12 mm192 24 ( )16 2 ( )Oil Fill Tube Bolt5 mm50 5 ( )-Oil Filter Pipe Fitting20 mm-35 4 ( )Oil Pick Up5 mm60 6 ( )-Oil Pressure Relief Plug10 mm-17 2 (23 )Oil Pump Housing Screw6 mm* 84 8 ( )-Rocker Arm8 mm-* 22 2 (30 3)Rocker Cover6 mm* 84 8 ( )-Spark Plug 14 mm216 24 ( )18 2 ( )Starter Motor6 mm* 84 8 ( )-Stator Assembly6 mm96 3 ( )-Stator Housing6 mm* 96 3 ( )-Stator Wire Retainer Plate5 mm* 96 3 ( )-Thermistor Sensor3/8 NPT-17 2 (23 3)Thermostat Housing6 mm84 8 ( )-Throttle Body Adaptor Bolts8 mm216 24 ( )18 2 ( )T-MAP Sensor Bolt5 mm25 3 ( )-Water Pump Housing Cover6 mm* 96 3 ( )-Water Pump Impeller Nut8 mm108 3 (12 )

6 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales EFI ENGINE Service SpecificationsCylinder Head - ENGINE SpecificationsMain Component: Cylinder HeadRGR800-11,XP (1204172)RGR800-12 (1204397); RGR800-12LK (1204486)CamshaftCam Lobe Height - ( mm)Cam Lobe Height - ( mm)Camshaft Journal Outer Diameter - Mag " " (42 mm)Camshaft Journal Outer Diameter - " " ( mm)Camshaft Journal Outer Diameter - " " (41 mm)Camshaft Journal Bore Inner Diameter - " " ( mm)Camshaft Journal Bore Inner Diameter - " " ( mm)Camshaft Journal Bore Inner Diameter - " " ( mm)Camshaft Oil Clearance " " ( mm)

7 Camshaft End " " ( mm)Counter BalanceCounter Balance End " ( mm)Cylinder HeadCylinder Head - Surface warp " ( mm)Cylinder Head - Standard " ( mm)Valve SeatValve Seat - Contacting Width - " " - " ( - mm)Valve Seat - Contacting Width - " " - "( - mm)Valve Seat Valve GuideValve Guide Inner " " ( mm)Valve Guide Protrusion Above " " ( mm)ValveValve Stem Diameter - " " ( mm)Valve Stem Diameter - " " ( mm)Valve Stem Oil Clearance - " " ( mm)Valve Stem Oil Clearance - " " ( mm)Valve Stem Overall Length - " " ( mm)Valve Stem Overall Length - ".

8 01496" ( mm)Valve SpringValve Spring Overall Length - Free " ( mm)Valve Spring Overall Length - Installed HeightIntake - " ( mm) Exhaust - " ( mm) - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc. Cylinder / Piston - ENGINE SpecificationsMain Components: Cylinder / Piston / Connecting RodRGR800-11,XP (1204172)RGR800-12 (1204397); RGR800-12LK (1204486)CylinderCylinder - Surface warp limit (mating with cylinder head) " ( mm)Cylinder Bore - " (80 mm)Cylinder Taper " ( mm)Cylinder Out of Round " ( mm)Cylinder to Piston ".

9 00059" (.040 .015 mm)LifterLifter Outer Diameter " " ( 8 mm)Lifter Block " " ( mm)PistonPiston - " .00028" ( .007 mm)Piston Standard Inner Diameter of Piston Pin " .00012" ( mm)Piston PinPiston Pin Outer " - " (18 - mm)Piston Pin - Standard Clearance - Piston Pin to Pin " " ( mm)Piston Pin - Degree of FitPiston pin must be push fit (by hand) at 68 F (20 C)Piston / Connecting Rod / Crankshaft - ENGINE SpecificationsMain Components: Piston / Connecting RodRGR800-11,XP (1204172)RGR800-12 (1204397).

10 RGR800-12LK (1204486)Piston RingInstalledGapTop Ring - - " ( - mm)Top Ring - Limit> 15% LeakdownSecond Ring - - " ( - mm)Second Ring - Limit> 15% LeakdownOil Ring - " ( mm)Oil Ring - Limit> 15% LeakdownRing to Groove ClearanceTop Ring - " " ( mm)Top Ring - Limit> 15% LeakdownSecond Ring - " " ( mm)Second Ring - Limit> 15% LeakdownConnecting RodConnecting Rod Small End "- " (18 - mm)Connecting Rod Small End Radial " " ( mm)Connecting Rod Big End Side " " ( mm)Connecting Rod Big End Radial " " ( mm)CrankshaftCrankshaft Runout " ( mm) - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales ToolsSPX Corporation.