just an idea - why not add all the info on air intake mods with filters etc.
Important parts information for Rangers
With our membership growing at such a rapid rate we are getting a lot of requests for part numbers on the modifications our members have done to their Rangers. Hopefully this list will make it easier for our members to access this information.
Heres a summary of what you can expect from these parts:
SP ECU: Improved all around performance and higher rev limit on 05 and 06 XP's. THE SP ECU WILL NOT WORK WITH THE STOCK 07' and newer CAM. On 07 & newer the SP ECU will not allow you to unlock the rear end.
Aftermarket ECU's: Improved performance on all XP's when combined wih other parts such as cams and bored throttle body. They offer a raised rev limit, usually 7,000 RPM
White Clutch Spring for 05'-08'Rangers: This raises the RPM's approximetly 200 at takeoff, which puts it in the powerband a little more and smooths it out.
Seat support bracket: For 06',07',08'. The seat tends to crush the Injector wires and damage them. This bracket prevents that.
Sportsman 500 H.O. carb and cam: This mod adds considerable performance to 500 carbed Rangers.
Cams:Best mod for any 700 and 2010' 800s. Need to be used with a fuel controller or aftermarket ECU Baxy's thread on the cam install http://www.prcforum.com/viewtopic.php?t=12491
NGK Irridium and AC Delco Rapid FIre Platinum #9 plugs: Better spark plug.
K&N under hood Filter: Better low end and high end. Its probably a good idea to run a pre-filter.
Dobeck TFI: Adds fuel to XP's. This is a low budget Fuel controller, but it works decent on 05 and 06 stock Rangers. It adds too much fuel when combined with the Aftermarket ECU's. I am told it only helps with the low end on 07 and newer Rangers
Power Commander V: Adjust fuel, timing and rev limit to Rangers and RZRs.Adds more fuel than the Dobeck, and it allows more precise tuning of the fuel system, it is tuned with a laptop. The only downside is it is more complicated to set up.
Boonedocker fuel controller Adds more fuel to XP's. Has the ability to add more fuel than the Dobeck, and is easier for to operate than the Power Commander. It has a digital screen and pushbuttons to controll it. Does not raise the rev limit.
800 Kit: This is a kit that Desert Rat developed that replaces parts from the 700 with parts from the 800. It gives it more horsepower and torque.
Team Rapid Roller Secondary Clutches: These clutches provide better acceleration and power than the stock clutches are able to, and generally operate smoother.
Polaris parts finder link
www.PolarisPartsHouse.com
POLARIS PARTS
PART..................................PART #
08, 09 XP Belt.........................3211118 has been supersceded by 3211133
05-07,XP Belt......................3211106 has been superceded by the [s:dd9dc74712]3211130[/s:dd9dc74712], 3211161
08-09 XP Belt......................3211118
10' XP Belt..........................3211133
SP ECU...............................4011560
SP Cam for 05-06 Rangers...............2202723 Includes liftersSee the link below for Baxy's cam install directions
Gasket for use w/cam............5812936
White primary clutch spring....7041132 Heres a link on how to install the white spring and washer http://www.prcforum.com/viewtopic.php?t=39
New 06'-08'motor mount #....3021936
Hood Support bracket...........2203279
Seat support bracket............5251133 for 06' and newer.
Seat Peg Repair Kit..............2204383 Here is a link to instructions https://www.polarisdealers.com/DealerExtranet/Files/Kits/KitInstructions/9923162r01.pdf
Rubber front spring spacer.....2872655
Sportsman H.O.40MM Carb.....3131567 For 500's, with a 150 jet
Sportsman H.O. Cam.............3085855 For 500'sFor the 40MM Carb and H.O. cam use the BKR6E Spark Plug
Rubber clamp kit for windshields....2876192H
Pinion input seal 06-08................. 3610102
Red Axle Seals both same................3610146
TPS: 06-09 part #........................... 2410342
TPS repair kit part # for 05-'10 ranger 700/800efi - 2203801 (model 2011 ranger has a different harness)
Polaris Lube reference chart: http://www.purepolarisoil.com/pdf/Maint_guide_ATV_2011.pdf
New seat pins for 09 and newer........2204383 (KIT-SEAT MNT)
TBAP repair harness kit............2875542
Or here is an aftermarket harness that has better wires: http://www.otbpowersports.com/p1.htm
![]()
For those of you that don't know what the TBAP looks like, here's a pic of one that I had replaced:
![]()
Pic's and info' courtesy of Walk the Dog
TPS Settings
05', 07', 700's................................... .710 Volts
06', 08', 09' 700's............................. .660 Volts
"10" 800s...........................................690 - .730 vdc
"11" 800s............................................700+-.050
NOTE:
TPS Learn Function (2010 Models)
The TPS automatically learns the idle setting at every key-on
occurrence. This function provides more consistent calibration
by compensating for TPS drift. However, if the TPS reading gets
below .690 Vdc or above .730 Vdc, the learn function is set to
default to the last successfully learned point and the “Check
Engine” or “MIL” indicator will illuminate. Performing the
“TPS Adjustment” procedure will remedy this problem
TPS Sensor Tester: part # 2201519-A
Air idle "D" screw adjustment tool, cheap................ http://www.kmsperformance.com/shop/item.aspx?itemid=13
Parts needed for the 700 to 800 conversionPosted by Clayton74
2203068 1 EA KIT-CRANKSHAFT
5134837 1 EA SHAFT-BALANCE
2203740 1 EA KIT-CAMSHAFT 80
3021934 1 EA HEAD-CYLINDER,M
2203715 2 EA KIT-PISTON 800
1253564 1 EA ADAPTER-THROTTL
5247360 1 EA GASKET-BASE
5247359 1 EA GASKET-HEAD
5812936 1 EA GASKET-COVER,MA
7043318 4 EA SPRING, VALVE
5411895 2 EA SEAL-VALVE GUID
5136932 2 EA RETAINER-VALVE
4011599 1 EA ECU-1.1B,NO STA
John Deere Replacement cage for front differential, for 05' - 08' Rangers only
John Deere part # MIA10667
Replacement fan from Spal for 09 Rangers
From Universal Parts Inc. Phone# 866-730-7169.................................Part# Z4012
Heavy duty ball joints Posted by Commanderjjones
Heavy duty ball joints made by All Balls.......part # 12-2528. I know they probably fit several other Rangers and quads, but I can only confirm the '05 through '08 XP. They are quite a bit cheaper (from ebay) and so far have lasted as long as the OEM's and are still going......time will tell how MUCH better they are. I've got a little over 100 hours on them so far.....the OEM's that I've used have all been shot by then.
Heavy duty tie rod ends made by All Balls.......part #51-1030. According to the box, it fits: '08-'09 Ranger 500 2x4 / '04-'09 Ranger 500 4x4 / '05-'09 Ranger 700 4x4 / '02-'04 Ranger 500 6x6 / '06-'09 Ranger 700 6x6 / '06-09 RZR 600 / Ranger series 10 / Ranger series 11.
ECM Connectors to replace bad connectors, info provided by kid dynomite
The following are part numbers for the Plugs and connectors, seals and cavity plugs for the ECM found on the 05/06 700 Ranger XP's. With these part numbers you can have a pig-tail put together so you can replace the burnt plugs and or wires on these models without buying a whole wiring harness from Polaris. These are Delphi/Packard part numbers. I located a company in Texas called Mouser Eletronics www.mouser.com that sold me these items as I needed not just bulk sales only. They shipped same day and had great service. I hope this helps fellow PRC members who have had ECM and burned plug and or wire issues like I did.
The 16 pin plug - 15326666
The 14 pin Plug - 15326917
Connectors Pins for inside of Plugs - 15304718
Seals for the Plugs - 12191221 or 15366066 Note: you can use either one depending on supplier's stock.
Cavity Plugs for the Plug - 15305170
Boonedocker EFI Control Box......1500-0119
Dobeck TFI.............................FI-6026ST
Power Commander for 05-09 700s...................924-411
Replacement spark plugs for XP's
NGK Iridium Part # BKR7EIX
AC Delco Rapid FIre Platinum #9
Unifilter
Stock air filter replacement for Rangers........NU-8507ST 04-06 Ranger
NU-8514ST 06-08 Ranger
Air Fuel gauge parts
If you bought one of the KOSO Air FUel Ration guages from DDP or Bikeman and your 02 sensor died and gives false readings, here is the NAPA Part# the Bosch Part#12028 will replace the Koso AFR guage 02 sensor.
Automotive Stores
Grant Steering wheel adapter................4187 (Use 3674 for the '07,08',09 units, see this post. http://www.prcforum.com/viewtopic.php?t=1591&whichpage=1&SearchTerms=which,steering,wheel,adapter)
Under hood K&N Filter..........................RU-1770
Silk Pre-filter for K&N...........................RU-1470PK
Foam Pre-wrap for RU-1770..................25-3900
Napa Brake pads for Nethawks e brake fix....TS-7574-M link to Nethawks E brake fix http://www.prcforum.com/viewtopic.php?t=377&start=0
Napa Falcon transmission mount............602-1069 replacement for Polaris factory motor mount
O'Reilly replacement motor mount..........2-2172 same as Napa part
See this link for a picture showing how to check the motormount http://www.prcforum.com/viewtopic.php?t=278
Replacement wheel bearings...............federal mogel 510014 front, 510013 rear, available at any parts store.
Odessey Battery................................925LMJ
Deka Battery.....................................ETX30L
Replacement Fuel Pumps
Napa replacement fuel pump for carbed 500s..... POSI-FLO #610-1050Anybody doing this install should have on hand 2 barbs to attach the new pump to the ( I think 3/8") fuel lines
OREILLYS replacement fuel pump for 05' 700s AIR-TEX PUMP #E8198 SELLS FOR 69.99
06',07' XP fuel pump replacement.... airtex part#e2446 fuel pump 1999 ford escort
06'07' XP fuel pump replacement ....Car Quest fuel pump part # 69542
or Napa Bosch............................... #N69128
Car Quest pump sock part # FS154
Fuel Pump Strainer for 2006 Ranger XP 700 EFI Airtex FS321 $25.99 from AutoZone
08' 700 XP replace fuel pump.................................. Airtex #E2068
08' 00 XP...............................................................Airtex E2471
09' 700, 10' 800, XP ...............................................Airtex #E8335
'05 Ranger XP, Fuel Pump Strainer...........................Airtex # FS111.
Napa replacement Rear prop shaft u-joint, ............... #P338
New Radiator cap from Auto Zone # 7516
Heater Hose T-Fitting / 1�x1�x5/8�
Kats Heater part number: # KAT-28113
Carquest part number: # HTR-79906
XP Replacement oil filters:
Napa................................................1357
Wix..................................................51357
Purolator extra volume.........................PL14610
K&N .................................................198
500 Replacement oil filter:
Napa................................................PS1358.
Replacement gas cap .........................1-2515 From Snapper mower
Replacement Ignition Keys and Boot
You can buy the cover, and the blanks seperately from the switch.
Black Rubber Key Cover p#: 5433534 MSRP: $8.58
Key BLANKS(not pre-cut, buy the blank then take it to a keycutting place to get a blank, replica of factory key & fits rubber key covers)
On top of your key there will be a 4 digit number, under the cover.
The first TWO numbers are what you need to be concerned with.
Key blank p#'s as follows:
20_ _ or 21_ _ or 67_ _ or 68_ _=p# 4010278 $7.66
22_ _ or 23_ _ or 27_ _ or 28_ _=p# 4010321 $7.66
31_ _ =p# 4110141 $8.58
32_ _ =p# 4110148 $8.58
Front differential fluids
There are three other alternatives that are approved by Hilliard. First is John Deere oil labeled as J20D. Second, Mobil Fluid LT. Third is Gulf Low Temperature Tractor Oil SAE 5W-20 API GL-4. The last two are more common and can be found in many tractor supply stores.
Lucas Oils Posted by Chiefmorton in a different thread
Here's what I used,
Engine - Lucas 0W-40 2 quarts
Front Diff - Lucas 75/90 gear oil, 5 oz.
Rear Diff - Lucas 75/90 gear oil, 18 oz.
Tranny - Lucas Semi-synthetic Sure Shift Transmission fluid, 15.2 oz
We would like to encourage members to use our sponsors at the
bottom of the home page to purchase these items, as they help to keep this site free.
Heres a summary of what you can expect from these parts:
SP ECU: Improved all around performance and higher rev limit on 05 and 06 XP's. THE SP ECU WILL NOT WORK WITH THE STOCK 07' and newer CAM. On 07 & newer the SP ECU will not allow you to unlock the rear end.
Aftermarket ECU's: Improved performance on all XP's when combined wih other parts such as cams and bored throttle body. They offer a raised rev limit, usually 7,000 RPM
White Clutch Spring for 05'-08'Rangers: This raises the RPM's approximetly 200 at takeoff, which puts it in the powerband a little more and smooths it out.
Seat support bracket: For 06',07',08'. The seat tends to crush the Injector wires and damage them. This bracket prevents that.
Sportsman 500 H.O. carb and cam: This mod adds considerable performance to 500 carbed Rangers.
Cams:Best mod for any 700 and 2010' 800s. Need to be used with a fuel controller or aftermarket ECU Baxy's thread on the cam install http://www.prcforum.com/viewtopic.php?t=12491
NGK Irridium and AC Delco Rapid FIre Platinum #9 plugs: Better spark plug.
K&N under hood Filter: Better low end and high end. Its probably a good idea to run a pre-filter.
Dobeck TFI: Adds fuel to XP's. This is a low budget Fuel controller, but it works decent on 05 and 06 stock Rangers. It adds too much fuel when combined with the Aftermarket ECU's. I am told it only helps with the low end on 07 and newer Rangers
Power Commander V: Adjust fuel, timing and rev limit to Rangers and RZRs.Adds more fuel than the Dobeck, and it allows more precise tuning of the fuel system, it is tuned with a laptop. The only downside is it is more complicated to set up.
Boonedocker fuel controller Adds more fuel to XP's. Has the ability to add more fuel than the Dobeck, and is easier for to operate than the Power Commander. It has a digital screen and pushbuttons to controll it. Does not raise the rev limit.
800 Kit: This is a kit that Desert Rat developed that replaces parts from the 700 with parts from the 800. It gives it more horsepower and torque.
Team Rapid Roller Secondary Clutches: These clutches provide better acceleration and power than the stock clutches are able to, and generally operate smoother.
Polaris parts finder link
www.PolarisPartsHouse.com
POLARIS PARTS
PART..................................PART #
08, 09 XP Belt.........................3211118 has been supersceded by 3211133
05-07,XP Belt......................3211106 has been superceded by the [s:dd9dc74712]3211130[/s:dd9dc74712], 3211161
08-09 XP Belt......................3211118
10' XP Belt..........................3211133
SP ECU...............................4011560
SP Cam for 05-06 Rangers...............2202723 Includes liftersSee the link below for Baxy's cam install directions
Gasket for use w/cam............5812936
White primary clutch spring....7041132 Heres a link on how to install the white spring and washer http://www.prcforum.com/viewtopic.php?t=39
New 06'-08'motor mount #....3021936
Hood Support bracket...........2203279
Seat support bracket............5251133 for 06' and newer.
Seat Peg Repair Kit..............2204383 Here is a link to instructions https://www.polarisdealers.com/DealerExtranet/Files/Kits/KitInstructions/9923162r01.pdf
Rubber front spring spacer.....2872655
Sportsman H.O.40MM Carb.....3131567 For 500's, with a 150 jet
Sportsman H.O. Cam.............3085855 For 500'sFor the 40MM Carb and H.O. cam use the BKR6E Spark Plug
Rubber clamp kit for windshields....2876192H
Pinion input seal 06-08................. 3610102
Red Axle Seals both same................3610146
TPS: 06-09 part #........................... 2410342
TPS repair kit part # for 05-'10 ranger 700/800efi - 2203801 (model 2011 ranger has a different harness)
Polaris Lube reference chart: http://www.purepolarisoil.com/pdf/Maint_guide_ATV_2011.pdf
New seat pins for 09 and newer........2204383 (KIT-SEAT MNT)
TBAP repair harness kit............2875542
Or here is an aftermarket harness that has better wires: http://www.otbpowersports.com/p1.htm
For those of you that don't know what the TBAP looks like, here's a pic of one that I had replaced:
Pic's and info' courtesy of Walk the Dog
TPS Settings
05', 07', 700's................................... .710 Volts
06', 08', 09' 700's............................. .660 Volts
"10" 800s...........................................690 - .730 vdc
"11" 800s............................................700+-.050
NOTE:
TPS Learn Function (2010 Models)
The TPS automatically learns the idle setting at every key-on
occurrence. This function provides more consistent calibration
by compensating for TPS drift. However, if the TPS reading gets
below .690 Vdc or above .730 Vdc, the learn function is set to
default to the last successfully learned point and the “Check
Engine” or “MIL” indicator will illuminate. Performing the
“TPS Adjustment” procedure will remedy this problem
TPS Sensor Tester: part # 2201519-A
Air idle "D" screw adjustment tool, cheap................ http://www.kmsperformance.com/shop/item.aspx?itemid=13
Parts needed for the 700 to 800 conversionPosted by Clayton74
2203068 1 EA KIT-CRANKSHAFT
5134837 1 EA SHAFT-BALANCE
2203740 1 EA KIT-CAMSHAFT 80
3021934 1 EA HEAD-CYLINDER,M
2203715 2 EA KIT-PISTON 800
1253564 1 EA ADAPTER-THROTTL
5247360 1 EA GASKET-BASE
5247359 1 EA GASKET-HEAD
5812936 1 EA GASKET-COVER,MA
7043318 4 EA SPRING, VALVE
5411895 2 EA SEAL-VALVE GUID
5136932 2 EA RETAINER-VALVE
4011599 1 EA ECU-1.1B,NO STA
John Deere Replacement cage for front differential, for 05' - 08' Rangers only
John Deere part # MIA10667
Replacement fan from Spal for 09 Rangers
From Universal Parts Inc. Phone# 866-730-7169.................................Part# Z4012
Heavy duty ball joints Posted by Commanderjjones
Heavy duty ball joints made by All Balls.......part # 12-2528. I know they probably fit several other Rangers and quads, but I can only confirm the '05 through '08 XP. They are quite a bit cheaper (from ebay) and so far have lasted as long as the OEM's and are still going......time will tell how MUCH better they are. I've got a little over 100 hours on them so far.....the OEM's that I've used have all been shot by then.
Heavy duty tie rod ends made by All Balls.......part #51-1030. According to the box, it fits: '08-'09 Ranger 500 2x4 / '04-'09 Ranger 500 4x4 / '05-'09 Ranger 700 4x4 / '02-'04 Ranger 500 6x6 / '06-'09 Ranger 700 6x6 / '06-09 RZR 600 / Ranger series 10 / Ranger series 11.
ECM Connectors to replace bad connectors, info provided by kid dynomite
The following are part numbers for the Plugs and connectors, seals and cavity plugs for the ECM found on the 05/06 700 Ranger XP's. With these part numbers you can have a pig-tail put together so you can replace the burnt plugs and or wires on these models without buying a whole wiring harness from Polaris. These are Delphi/Packard part numbers. I located a company in Texas called Mouser Eletronics www.mouser.com that sold me these items as I needed not just bulk sales only. They shipped same day and had great service. I hope this helps fellow PRC members who have had ECM and burned plug and or wire issues like I did.
The 16 pin plug - 15326666
The 14 pin Plug - 15326917
Connectors Pins for inside of Plugs - 15304718
Seals for the Plugs - 12191221 or 15366066 Note: you can use either one depending on supplier's stock.
Cavity Plugs for the Plug - 15305170
Boonedocker EFI Control Box......1500-0119
Dobeck TFI.............................FI-6026ST
Power Commander for 05-09 700s...................924-411
Replacement spark plugs for XP's
NGK Iridium Part # BKR7EIX
AC Delco Rapid FIre Platinum #9
Unifilter
Stock air filter replacement for Rangers........NU-8507ST 04-06 Ranger
NU-8514ST 06-08 Ranger
Air Fuel gauge parts
If you bought one of the KOSO Air FUel Ration guages from DDP or Bikeman and your 02 sensor died and gives false readings, here is the NAPA Part# the Bosch Part#12028 will replace the Koso AFR guage 02 sensor.
Automotive Stores
Grant Steering wheel adapter................4187 (Use 3674 for the '07,08',09 units, see this post. http://www.prcforum.com/viewtopic.php?t=1591&whichpage=1&SearchTerms=which,steering,wheel,adapter)
Under hood K&N Filter..........................RU-1770
Silk Pre-filter for K&N...........................RU-1470PK
Foam Pre-wrap for RU-1770..................25-3900
Napa Brake pads for Nethawks e brake fix....TS-7574-M link to Nethawks E brake fix http://www.prcforum.com/viewtopic.php?t=377&start=0
Napa Falcon transmission mount............602-1069 replacement for Polaris factory motor mount
O'Reilly replacement motor mount..........2-2172 same as Napa part
See this link for a picture showing how to check the motormount http://www.prcforum.com/viewtopic.php?t=278
Replacement wheel bearings...............federal mogel 510014 front, 510013 rear, available at any parts store.
Odessey Battery................................925LMJ
Deka Battery.....................................ETX30L
Replacement Fuel Pumps
Napa replacement fuel pump for carbed 500s..... POSI-FLO #610-1050Anybody doing this install should have on hand 2 barbs to attach the new pump to the ( I think 3/8") fuel lines
OREILLYS replacement fuel pump for 05' 700s AIR-TEX PUMP #E8198 SELLS FOR 69.99
06',07' XP fuel pump replacement.... airtex part#e2446 fuel pump 1999 ford escort
06'07' XP fuel pump replacement ....Car Quest fuel pump part # 69542
or Napa Bosch............................... #N69128
Car Quest pump sock part # FS154
Fuel Pump Strainer for 2006 Ranger XP 700 EFI Airtex FS321 $25.99 from AutoZone
08' 700 XP replace fuel pump.................................. Airtex #E2068
08' 00 XP...............................................................Airtex E2471
09' 700, 10' 800, XP ...............................................Airtex #E8335
'05 Ranger XP, Fuel Pump Strainer...........................Airtex # FS111.
Napa replacement Rear prop shaft u-joint, ............... #P338
New Radiator cap from Auto Zone # 7516
Heater Hose T-Fitting / 1�x1�x5/8�
Kats Heater part number: # KAT-28113
Carquest part number: # HTR-79906
XP Replacement oil filters:
Napa................................................1357
Wix..................................................51357
Purolator extra volume.........................PL14610
K&N .................................................198
500 Replacement oil filter:
Napa................................................PS1358.
Replacement gas cap .........................1-2515 From Snapper mower
Replacement Ignition Keys and Boot
You can buy the cover, and the blanks seperately from the switch.
Black Rubber Key Cover p#: 5433534 MSRP: $8.58
Key BLANKS(not pre-cut, buy the blank then take it to a keycutting place to get a blank, replica of factory key & fits rubber key covers)
On top of your key there will be a 4 digit number, under the cover.
The first TWO numbers are what you need to be concerned with.
Key blank p#'s as follows:
20_ _ or 21_ _ or 67_ _ or 68_ _=p# 4010278 $7.66
22_ _ or 23_ _ or 27_ _ or 28_ _=p# 4010321 $7.66
31_ _ =p# 4110141 $8.58
32_ _ =p# 4110148 $8.58
Front differential fluids
There are three other alternatives that are approved by Hilliard. First is John Deere oil labeled as J20D. Second, Mobil Fluid LT. Third is Gulf Low Temperature Tractor Oil SAE 5W-20 API GL-4. The last two are more common and can be found in many tractor supply stores.
Lucas Oils Posted by Chiefmorton in a different thread
Here's what I used,
Engine - Lucas 0W-40 2 quarts
Front Diff - Lucas 75/90 gear oil, 5 oz.
Rear Diff - Lucas 75/90 gear oil, 18 oz.
Tranny - Lucas Semi-synthetic Sure Shift Transmission fluid, 15.2 oz
We would like to encourage members to use our sponsors at the
bottom of the home page to purchase these items, as they help to keep this site free.
2
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1 - 20 of 177 Posts
