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CHAPTER 3 ENGINE - Polaris ATV | Alternative Support

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.. ENGINE SERVICE .. INTAKE RESTRICTOR ORIFICE .. COMPONENTS.. LUBRICATION SPECIFICATIONS / OIL PRESSURE TEST .. FLOW CHART .. REMOVAL .. INSTALLATION NOTES .. DISASSEMBLY AND INSPECTION.

ENGINE 9923499 - 2011 / 2012 RANGER 800 Service Manual © Copyright 2011 Polaris Sales Inc. =

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Transcription of CHAPTER 3 ENGINE - Polaris ATV | Alternative Support

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.. ENGINE SERVICE .. INTAKE RESTRICTOR ORIFICE .. COMPONENTS.. LUBRICATION SPECIFICATIONS / OIL PRESSURE TEST .. FLOW CHART .. REMOVAL .. INSTALLATION NOTES .. DISASSEMBLY AND INSPECTION.

2 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 .. 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.

3 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 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.

4 (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 )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 ( )

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 ) - 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).

6 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)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 - ".

7 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 " .00059" (.040 .015 mm)LifterLifter Outer Diameter " " ( 8 mm)Lifter Block " " ( mm)PistonPiston - ".

8 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); 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)

9 - 2011 / 2012 ranger 800 Service manual Copyright 2011 Polaris Sales ToolsSPX Corporation: 1-800-328-6657 or NumberTool DescriptionPU-50105 OIL FILTER WRENCHPU-45257 VALVE SPRING COMPRESSORPU-45652 VALVE PRESSURE HOSE2871043 FLYWHEEL PULLER2870390 PISTON Support BLOCKPU-45497-1 CAM GEAR SPRING INSTALLATION KITPU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOLPU-45498 CAM SPANNER WRENCHPU-45838 GEAR HOLDERPA-44995 WATER PUMP MECHANICAL SEAL INSTALLERPU-45543 UNIVERSAL DRIVER HANDLEPA-45483 MAIN SEAL INSTALLERPU-45658 CRANKSHAFT MAIN SEAL SAVERPA-45401 WATER PUMP SEAL SAVER2870975 MITY VAC PRESSURE TEST TOOLPU-45778 OIL SYSTEM PRIMING - 2011 / 2012 ranger 800 Service manual Copyright 2011 Polaris Sales COOLING SYSTEMC ooling System SpecificationsRecommended CoolantUse only high

10 Quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area. IMPORTANT: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible ENGINE damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for System Pressure Test1. Open the front Remove the pressure cap from the radiator and pressure test the cooling system using a commercially available The system must maintain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the radiator, all cooling system hoses, clamps and water pump seal for Cap Pressure Test1.


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