Polaris XP Doors (P144202) Installation Instructions

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Polaris XP4 000 Doors (P440) Installation Instructions WARNING Pro Armor Door and Net are designed to work together to replace your original equipment nets and/or door.

Use of nets may help keep you from sticking your arm out of the vehicle during a rollover.

trained technicians inspect your installation Pro Armor recommends you do not use your UTV if installation of the Door, Net, and Slam Latch Kit is incomplete Pro Armor Door and Net are designed to

1 Polaris XP4 000 Doors (P440) Installation Instructions WARNING Pro Armor Door and Net are designed to work together to replace your original equipment nets and/or door. Install both the Pro Armor Door and Pro Armor Net to meet occupant protection standards (ANSI/ROHVA- effective model year 04). Use of nets may help keep you from sticking your arm out of the vehicle during a rollover. If you have questions about your installation, are unable able to complete installation, or your door is not working correctly contact Pro Armor Customer Service or have an authorized dealer or trained technicians inspect your installation Pro Armor recommends you do not use your UTV if installation of the Door, Net, and Slam Latch Kit is incomplete Pro Armor Door and Net are designed to work with the seat belt and other safety features provided by the manufacturer, along with proper preparation and responsible driving from the driver Pro Armor recommends you follow all manufacturers instructions when preparing to ride and during operation If you have any questions contact us at or WWW PROARMOR COM Disclaimer Please read: This product is sold without warranty expressed or implied No warranty or representation is made as to the products ability to protect the user / occupant from any injury or death in any manner of use The user assumes that risk. The effectiveness of this equipment is directly related to the manner in which it is installed, used, and / or maintained Proper installation is solely the responsibility of the install-

NOTICE Due to the production variances and differing conditions of the frame, door adjustments may be necessary to avoid rubbing and proper fit Ensure proper fit before tightening hardware and

If adjustment is necessary, confirm all mounting points are secured Gently pull on the front or rear door frames to adjust positioning of the door in the frame HARDWARE LIST: ITEM #: DESCRIPTION:

2 NOTICE Due to the production variances and differing conditions of the frame, door adjustments may be necessary to avoid rubbing and proper fit Ensure proper fit before tightening hardware and continuing with installation! If adjustment is necessary, confirm all mounting points are secured Gently pull on the front or rear door frames to adjust positioning of the door in the frame HARDWARE LIST: ITEM #: DESCRIPTION: QTY: Driverside Slam Latch Passenger Side Slam Latch 3 Latch Fastener 4 4 Washer, M6 Narrow, Black Zinc 8 5 Bolt, M6 x 00 x 30mm Button Head Bolt 8 6 Nut, M8 x 5 Nyloc Flanged Hex Head 7 Bolt, M8 x 5 x 5mm Flanged Head 8 Bolt, M6 x 5 x 6mm Button Flang Head Black Zinc 8 9 M6 x 0 Acorn Hex Nut, Black Zinc 8 PART DESCRIPTION QTY FRONT DOOR ASSEMBLY (L) FRONT DOOR ASSEMBLY (R) 3 REAR DOOR ASSEMBLY (L) 4 REAR DOOR ASSEMBLY (R) PREPARATION and STOCK DOOR REMOVAL: FIG. # FIG. # Use a T40 torx to remove the stock front doors from the stock hinge brackets Leave the bracket connected to the hinges Remove all 4 bolts and save them for install of the PA doors See figure # Repeat for opposite side front door 3 Use a 5mm Socket and a 5mm open end wrench to remove the bolts in the upper mount on the rear doors You will re-use these bolts See Fig # 4 Use a 3mm Socket and ratchet to remove the bolt on the lower mount of the rear door You will not use this bolt anymore See Fig # 5 Do one side at a time to avoid the cage being out of alignment when the mounting bolts are removed NOTICE If the mounting hole alignment is off, you might need to use a jack to lift the vehicle This will aid in aligning the holes By lifting the middle of the vehicle, it will open the mounting area And by lifting the front or the rear of the vehicle, it will close the mounting area Due to the production variances and differing conditions of the frame, door adjustments may be necessary to avoid rubbing and proper fit Ensure proper fit before tightening hardware and continuing with installation! If adjustment is necessary, confirm all mounting points are secured Gently pull on the front or rear door frames to adjust positioning of the door in the frame

FRONT DRIVERSIDE DOOR Item #3 Item # Front Door Slam Latch Installation: Use Item # Driverside Slam Latch and install like shown in Figure to the left Grab items #3 Latch Fastener, #4 Washer, & #5 M6

with the bracket to align it correctly and tighten down the bolts Item #4 4 Repeat steps -3 for the opposite side door except use the Item # Passenger Door Slam Latches instead Item #5 REAR

3 FRONT DRIVERSIDE DOOR Item #3 Item # Front Door Slam Latch Installation: Use Item # Driverside Slam Latch and install like shown in Figure to the left Grab items #3 Latch Fastener, #4 Washer, & #5 M6 Bolt, the washer will go on first then slide the bolt through the latch bracket on the door and start the threads into Item #3 3 Once both bolts have been started make sure the latch edge is parallel with the bracket to align it correctly and tighten down the bolts Item #4 4 Repeat steps -3 for the opposite side door except use the Item # Passenger Door Slam Latches instead Item #5 REAR DRIVERSIDE DOOR Item #3 Item # Rear Door Slam Latch Installation: Use Item # Driverside Slam Latch and install like shown in Figure to the left Grab items #3 Latch Fastener, #4 Washer, & #5 M6 Bolt, the washer will go on first then slide the bolt through the latch bracket on the door and start the threads into Item #3 3 Once both bolts have been started make sure the latch edge is parallel with the bracket to align it correctly and tighten down the bolts 4 Repeat steps -3 for the opposite side door except use the Item # Passenger Door Slam Latches instead Item #4 Item #5

FRONT DRIVERSIDE DOOR Item #9 Front Door Panel Installation: The front door has 7 of the Item #8 (M6 Bolt) and 7 of the Item #9 (M6 Acorn Nut) to secure the panel to the door frame Door Frame It is

4 FRONT DRIVERSIDE DOOR Item #9 Front Door Panel Installation: The front door has 7 of the Item #8 (M6 Bolt) and 7 of the Item #9 (M6 Acorn Nut) to secure the panel to the door frame Door Frame It is usually easier to put the top in first just hand tight, so this helps align and hold the panel in place while the others are installed See Figure to the left 3 While tightening the panel hardware, try to align the panel so the edges of the panel run parallel with the door frame tubes 4 Only hand tighten the top bolts because the nets will be installed later on and will attach to these tabs 5 The rest of the panel hardware can now be tightened securely 6 Repeat these steps for opposite side door Item #8 7 Be sure to check the hardware periodically to ensure they are secure Door Panel Item #9 Rear Door Panel Installation: Door Frame REAR DRIVERSIDE DOOR The rear door has 7 of the Item #8 (M6 Bolt) and 7 of the Item #9 (M6 Acorn Nut) to secure the panel to the door frame It is usually easier to put the top in first just hand tight, so this helps align and hold the panel in place while the others are installed See Figure to the left 3 While tightening the panel hardware, try to align the panel so the edges of the panel run parallel with the door frame tubes 4 Only hand tighten the top bolts because the nets will be installed later on and will attach to these tabs 5 The rest of the panel hardware can be tightened securely 6 Repeat these steps for opposite side door Item #8 7 Be sure to check the hardware periodically to ensure they are secure Door Panel

REAR DOOR INSTALLATION: Upper Mount It is usually easier to do one side at a time to keep the cage from moving with too many bolts loose Slide the top door mounting bracket over the cage use the

See figure on the left Make sure that there is clearance throughout this area of the door and the stock plastics before tightening the door.

will use a 5mm on both the bolt and the nuts The lower mount will need to use a wrench to fit in on the back side due to tight clearance for a socket to fit and tighten 5 Once the lower and upper

5 REAR DOOR INSTALLATION: Upper Mount It is usually easier to do one side at a time to keep the cage from moving with too many bolts loose Slide the top door mounting bracket over the cage use the stock cage hardware and hand tighten See Figure to the left Pull the stock plastics out just slightly so the lower door mount will fall into place on the outside of the stock lower door mounting tab See figure on the left Make sure that there is clearance throughout this area of the door and the stock plastics before tightening the door. Lower Mount Stock Door Striker 3 Make sure the gaps are clear from the plastics and do not rub See figure above 4 Once the door gaps are clear tighten the upper and lower door mounts The upper mount will use a 5mm on both the bolt and the nuts The lower mount will need to use a wrench to fit in on the back side due to tight clearance for a socket to fit and tighten 5 Once the lower and upper door mounts are tight and the door does not rub on plastic, loosen the bolts holding the stock striker in place using a T40 Torx head 6 Align the striker to run perpendicular to the latch and align it so the latch gear hits the striker in the area shown in the figure to the left Proper striker to latch alignment 7 Once you achieve this proper alignment, tighten the stock striker back up and tighten all the hardware on the door, other than the top panel bolts 8 Repeat steps for opposite side

FRONT DOOR INSTALLATION: Install front door frames by sliding the stock door brackets on the backside of the Pro Armor door mount brackets See figure to the left Use the stock

striker and align the striker so it catches the latch gear like shown on the figure on the bottom left Once this alignment is found, tighten the striker back to OEM specifications

latch alignment is found, you can fully tighten the four(4) T40 Torx bolts on the door brackets 6 Open and close the door a couple times to make sure it still works smoothly If it

6 FRONT DOOR INSTALLATION: Install front door frames by sliding the stock door brackets on the backside of the Pro Armor door mount brackets See figure to the left Use the stock hardware and hand tighten all four(4) bolts with a T40 Torx bit Do not tighten complete until final adjustment is made 3 Use a T40 Torx to loosen the bolts on the stock door striker and align the striker so it catches the latch gear like shown on the figure on the bottom left Once this alignment is found, tighten the striker back to OEM specifications in the manual 4 Make sure the top door tube alignment is level with the stock plastics like shown on the figure on the bottom right 5 Once the door tube alignment and the proper latch alignment is found, you can fully tighten the four(4) T40 Torx bolts on the door brackets 6 Open and close the door a couple times to make sure it still works smoothly If it does not, repeat the steps until the latch and door alignment are good 7 Make sure to check and tighten the hardware before each use Stock Door Brackets Stock T40 Torx Door Hardware PROPER ALIGNMENT

FRONT DOOR NET INSTALLATION: Place the net over the door like shown on the figure above and wrap

that you will tighten with the top door panel nut and bolt See figure above 3 Once the door straps

steps for other side REAR DOOR NET INSTALLATION: Place the net over the door like shown on the

on the left 3 Once the door straps are hooked, attach the rear straps to the cages rear c-pillar

Loop the strap around the stock cage tube that the lower mount on the door attaches to like shown

the right 3 Repeat steps for opposite side 4.

7 FRONT DOOR NET INSTALLATION: Place the net over the door like shown on the figure above and wrap the 3 Velcro straps securely around the top door frame tube There is one strap with a metal loop that you will tighten with the top door panel nut and bolt See figure above 3 Once the door straps are hooked, attach the rear straps to the cage b-pillar like shown on figure to the left Repeat steps for other side REAR DOOR NET INSTALLATION: Place the net over the door like shown on the figure to the left and wrap the 3 Velcro straps securely around the top door frame tube There is one strap with a metal loop that you will tighten with the top door panel nut and bolt See figure on the left 3 Once the door straps are hooked, attach the rear straps to the cages rear c-pillar like shown on figure to the left Repeat steps for other side REAR DOOR LIMIT STRAP INSTALLATION: Loop the strap around the stock cage tube that the lower mount on the door attaches to like shown on figure to the right Remove the panel hardware bolt and install the strap like shown on figure to the right 3 Repeat steps for opposite side 4. Make sure to check ALL hardware and make sure it is tight before each use!

RH-412 STEEL DOORS INSTALLATION INSTRUCTIONS

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