Length: 32:48
Created: June 21, 2024
What’s up guys, Braden here with SuperATV. Today, we’re going to be showing you how to install SuperATV’s full aluminum doors on this Polaris RZR Pro R4, so let’s get right to it.
The first step is to open the door and remove the seat from the machine. To do this, grab the latch at the front of the seat and lift it out. Set the seat aside. Next, remove the panel by taking out the push pins. There are push pins located on the panel: one at the bottom, three on the side, and one at the top (if present). Use a push pin puller to remove them. Once all the push pins are out, remove the panel and set it aside.
Now, we need to remove the doors completely from the machine. There are two 13 mm headed bolts at the top and two at the bottom of the door hinges. Begin by removing the bottom bolts first, then move to the top bolts while holding the door to prevent it from falling. Retain this hardware as it will be reused for installing the new doors. Carefully remove the door and take it to a benchtop for the next steps.
To separate the door skin from the door frame, you need to remove the T40 screws throughout the door frame and the T25 clamp at the bottom. Our demonstration door has fewer screws for simplicity. Once all hardware is removed, separate the door skin from the frame and discard the skin, as it will not be reused.
Next, remove the door handle using a T30 Torx. It can be helpful to use an impact tool to provide an abrupt shock that helps to bust the bolts loose. If this is the first time these screws are being removed, consider applying slight heat to the back side of the screws to break loose any thread locker. Retain the factory hardware. After removing the handle, use an 8 mm socket to remove the latch. Again, retain the factory hardware.
Carefully remove the clips and pins from the door hinges. On the bottom side of the pins, there are clips that can be removed with a flat blade screwdriver. Be careful not to lose these clips as they will be reused. If the pins are frozen, spray some lubricant and use a punch and hammer to gently tap them out.
Attach the provided hinge brackets to the new door frame using the pins removed earlier. The top bracket will have a gusset piece that should face towards the inside of the door (towards the handle). Insert the pin through the bracket and into the frame. Use a hammer to tap the pin gently until it is fully seated, and the clip groove is exposed. Repeat the process for the lower bracket.
Reattach the door handle to the new frame using the retained factory hardware. Center the handle in its notch and snug the screws. Install the latch using the 8 mm screws, ensuring it aligns properly. Check the handle operation to make sure it functions correctly.
Attach the provided brackets to the side filler panel. The top bracket has a gusset and should be oriented correctly, with the gusset facing towards the inside of the panel. Leave the screws slightly loose for adjustments. The bottom bracket should be attached similarly.
Install the side bracket on the machine’s frame using the provided 10 mm headed bolts and Nylock nuts. The bracket should fit into the factory holes on the machine. Adjust the bracket to align with the holes and snug the bolts to hold it in place, but do not fully tighten yet.
Secure the side filler panel to the previously installed bracket using M6 flange head Allen screws. Adjust the panel for a tight fit against the fender and fully tighten the screws. Ensure the panel is pulled back as far as possible to provide clearance for the door.
Mark the locations for the lower brackets on the machine’s plastic. Drill holes large enough to fit 6 mm bolts (7 mm for some adjustment room). Attach the lower brackets using M6 Allen screws and Nylock nuts. Adjust the brackets for proper alignment and snug the hardware.
Reinstall the side panel, starting with the front brackets. Apply rear pressure to the panel to pull it back as far as possible and snug the hardware to secure it. This ensures the door will clear the panel properly.
Remove the factory door striker and install the provided striker bracket using the factory hardware. Attach the new striker with a 6 mm Allen and 17 mm wrench. Ensure it is properly aligned and fully tightened.
Latch the door frame to the striker to hold it in place. Secure the frame to the machine’s frame using the retained hardware and provided Nylock nuts. Adjust the frame for proper fit and functionality. Ensure the door opens and closes smoothly.
Line up and attach the new door skin to the frame using the screws removed earlier. Adjust the skin for proper alignment and fully tighten all hardware.
Adjust the door to ensure it opens and closes smoothly without binding. Ensure an even gap between the door and side panel. Snug all hardware securely. Make any final adjustments to the striker and brackets as needed. We’ve shown you everything you need to know about installing these doors on the Pro R. Follow the same steps for the driver’s side. Double-check all hardware and adjustments. That’s it for installing Super ATV’s full aluminum doors on the Polaris RZR Pro R. Check the description below to pick yours up today. Don’t forget to like, comment, and subscribe. We’ll catch you on the next one.
