Length: 25:18
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 aluminum doors on this Polaris RZR Pro R 4, 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 back of the seat and pull it out. Set the seat aside. Next, flip the seat base up and remove the front seats by unscrewing the two bolts at the base. Set these bolts aside for later use.
At the bottom of the door, there are two bolts that need to be removed. Use a suitable tool to unscrew them and set them aside. Move to the front door and remove the two factory bolts securing it. Again, retain these bolts as they will be reused in later steps.
Next, remove enough of the door skin hardware, which are T40 bolts, to detach the handle. Use a T30 Torx bit to remove the handle bolts. It’s recommended to use an impact tool to provide an abrupt shock that helps to bust the bolts loose. Applying downward pressure on the tool will prevent the bolts from stripping.
After removing the handle, use an 8 mm socket to remove the two bolts holding the latch in place. Retain all the hardware as it will be reused. Following this, remove the pins from the factory hinges. Use a flat screwdriver to pry off the clips and then push the pins out. If the pins are stuck, use a punch and hammer to gently tap them out.
To remove the door skin, unscrew all the T25 bolts securing it to the frame. Separate the door frame from the skin and set the skin aside as it will not be reused. Remove the handle from the frame and set it aside.
Remove the hinges by taking off the clips and pins that hold them in place. Use a screwdriver to pry off the clips and carefully slide out the pins. Set these components aside as they will be reused in the installation of the new door components.
Grab the filler panel bracket for the correct side you are working on (passenger side in this case) and slide it into position. The bracket should fit into the factory holes on the machine. Line up the threaded clip with the hole in the plastic and start the hardware. Once aligned, snug the hardware to hold the bracket in place but do not fully tighten it yet.
Attach the filler panel using the M6x12 mm Allen bolts provided in the kit. Push the panel back into the fender to ensure a tight fit. Secure it with the small 90° bracket, aligning it with the holes in the panel. Hand-tighten the hardware initially to hold it in place.
Mark the locations for the lower brackets on the machine’s plastic. Drill the marked holes to a size of at least 6.5 mm, ensuring that there is nothing below the drilling area that could be damaged. Install the M6x20 mm hardware through the drilled holes and snug it up, allowing some movement for final adjustments.
Secure the filler panel by pushing it back as far as it will go and fully tightening the hardware. Ensure that all brackets are properly positioned and tightened. This will provide a secure base for the new door components.
Install the rear lower hinge bracket using the factory hardware and shims provided in the kit. Hand-tighten the hardware initially to hold the bracket in place. Use a 13 mm socket to snug the bolts, ensuring the bracket is secure. This bracket will support the lower part of the new door.
Attach the upper hinge mount using the factory hardware and M8 Nylock nuts. Line up the bracket with the holes and start the hardware. Ensure that the bracket is correctly positioned and secure it by tightening the nuts.
Attach the lower hinge bracket (part U) and upper hinge bracket (part T) to the machine. The lower hinge bracket is identified by its long gusset, while the upper hinge bracket has a shorter gusset. Align the brackets with the holes and secure them with the factory bolts and provided Nylock nuts. This will provide the mounting points for the new doors.
Remove the factory striker bolts and install the striker bracket using the spacers and long M8 bolts provided. Ensure the bracket bends towards the front. Line up the holes with the factory locations and snug the hardware. This bracket will hold the new door striker.
Remove the front factory striker and replace it with the provided striker from the kit. Secure it with the factory hardware and snug it up. This striker will align with the new door latch.
Transfer all factory components, starting with the handle, into the new door frame. Use the retained factory hardware to secure the handle and latch. Ensure that the handle and latch are properly aligned and functioning correctly.
Latch the rear door onto the striker and align it with the hinges. Insert the pins into the hinges and secure them with clips. Adjust the alignment to ensure the door opens and closes smoothly. Snug the hardware but do not fully tighten until final adjustments are made.
Adjust the door alignment to ensure it opens and closes smoothly. Snug the hardware and make final adjustments as necessary. Check the alignment and functionality of the door repeatedly to ensure it operates correctly.
Adjust the striker, latch, and handle to ensure proper alignment and functionality. There are multiple adjustment points, so take your time to fine-tune the door fitment. Ensure all adjustment points are tight and the doors open and close properly without any binding.
Latch the front door onto the striker and align it with the hinges. Insert the pins and secure them with clips. Snug the hardware and make final adjustments to ensure proper alignment and smooth operation.
Ensure that both the front and rear doors are properly aligned and adjusted. This may take some time and fine-tuning to get right. Check all adjustment points and make necessary tweaks to achieve an even gap and smooth operation.
Repeat the same steps for the opposite side, mirroring the process. Ensure all hardware is tight and doors are properly adjusted. Once everything is aligned and functioning correctly, the installation is complete. That’s all there is to it to install Super ATV’s full aluminum doors on the Polaris RZR Pro R4. Be sure to check the description below to pick yours up today. While you’re there, drop a like, comment, and subscribe. We’ll catch you on the next one.
