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High Lifter PGL-KIT-RZRT, Manual, Page: 27 / 34

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High Lifter PGL-KIT-RZRT Manual Download Page 27

 

PGL-KIT-RZRT 

 

27 

20.

 

INSTALL REAR BRAKE HANGER BRACKET AND CALIPER 

a.

 

Remove the factory rear brake caliper hanger bracket from the rear brake caliper. 

 

 
b.

 

Find the new rear brake caliper hanger bracket 

PGLC-BCB-1912496 

and insert it into the brake caliper. 

 

 
c.

 

Install the caliper onto the portal box between the new caliper bracket and rotor. Use the supplied 

M10X1.25X25 bolts

. 

Position brake line banjo fitting clocked to 10 o’clock so it runs at the proper angle for 

maximum suspension travel.  Tighten & torque to specifications. (15mm) [50 ft lbs] 

NOTE:  Remember, the bleed off valve always goes to the TOP of the caliper.

 

 

  

 
 
 
 
 
 

Summary of Contents for PGL-KIT-RZRT

Page 1: ...PGL KIT RZRT 1...

Page 2: ...vel ground Operation of an ATV and or RUV with or without modified suspension components while or shortly after consuming alcohol or drugs subjects the rider and passengers to the risk of serious bodi...

Page 3: ...vehicle s dash within driver s view The Warning to Driver decal is to act as a constant safety reminder for whoever may be operating the vehicle INSTALLING dealer It is your responsibility to install...

Page 4: ...tener torque specs assembly techniques and special tool requirements that are unique to this particular year and model vehicle TORQUE SPECIFICATIONS Check all brackets bolts to be sure everything is t...

Page 5: ...7 Assemble brake rotor and wheel hubs 8 Install front brake rotor assembly 9 Adjust front camber 10 Replace route front brake lines 11 Install front brake calipers 12 Install front tires and wheels RE...

Page 6: ...PGL KIT RZRT 6 PARTS DIAGRAM...

Page 7: ...PGL KIT RZRT 7...

Page 8: ...frame and not the body d Make sure the unit is stable and secure Remove wheel nuts and front wheels 2 REMOVAL OF FRONT BRAKE CALIPER AND HUB a Remove the upper lower caliper mounting bolts 15mm b Rem...

Page 9: ...and then remove the hub f Remove the front brake rotor assembly g Disconnect the tie rod 18mm h Remove upper ball joint pinch bolt from the knuckle 15mm Then remove the lower ball joint nut from the...

Page 10: ...he front right upper ball joint mount bracket 82B R Place it on top of the shim and make sure all the holes are aligned The small cut out should be to the top right d Insert 7 16 x 2 1 4 bolts through...

Page 11: ...bolt mount Note You may need to clean powder coating from the holes If you are using stock or non forward raked arms then insert the factory bolt and fasten with the factory nut Torque front ball join...

Page 12: ...se this lock washer for the front boxes Just insert the x 1 bolt through the upper hole of the caliper mounting bracket PGLC BCB 85Y and place it in the corresponding fitted section of the front porta...

Page 13: ...inner drive gear c Insert the bolts through the corresponding holes in the backing plate d Loosely fasten the 4 bolts with flat washers and lock nuts Recheck all parts that were used and make sure ev...

Page 14: ...properly aligned into the drive gear of the portal box b Apply LOCTITE 243 Blue to the supplied M18 axle nut with shoulder PGLC AXNUT and tighten torque onto the drive shaft axle 27mm 180 ft lbs c Al...

Page 15: ...her This side will face away from the UTV when installed Place this side face down on your working surface for the following steps c With the shorter lip side faced down find the bolt pattern that cor...

Page 16: ...s f Locate a brake rotor PGLC ROTOR The side with the counter bores should be facing up Place the rotor on to the hub and line the holes up with the tapped holes g Apply LOCTITE RED to 4 3 8 16 x 1 bu...

Page 17: ...lied large cotter pin Both ends of the cotter pin must be folded 9 ADJUST FRONT CAMBER a When checking the camber it is necessary that the unit is leveled You can do this by properly positioning jack...

Page 18: ...upper ball joint mount bracket from the portal box You can leave the portal box attached to the lower ball joint and leave the mount bracket attached to the upper ball joint while you change shims in...

Page 19: ...ut it in a Zip Loc bag and label it DR side front Put it where you can find it if needed It will not be reused during this installation a Disconnect both brake lines from the calipers and free the lin...

Page 20: ...side hub d Use the existing factory PA side brake line and install it to the banjo bolt This is replacing the factory DR side brake line e The factory brake line banjo bolt should be in this sequence...

Page 21: ...o it runs at the proper angle for maximum suspension travel Tighten torque to specifications 13mm 50 ft lbs e Use the factory A arm clips and the supplied 8 zip ties to reposition the brake lines 12 I...

Page 22: ...BS a Remove the brake line guide Retain factory hardware b Remove the upper lower caliper mounting bolts 15mm c Remove the caliper from the rear hub It is not necessary to remove the brake line from t...

Page 23: ...plate PGLC BP RZR1AL4 RR as shown below and place it flush to the trailing arm c Follow the steps below to install and fasten the backing plate to the trailing arm 1 Insert a 3 8 x 1 bolt with a 10mm...

Page 24: ...apply product all around the outer edge as well Rotate the portal box assembly Up In as you guide the drive shaft axle through the inner drive gear 1 Slide a single 1 2 flat washer onto 2 x 4 bolts In...

Page 25: ...need to remove a shim You are provided a 1 8 shim and a 1 16 shim for each portal to better achieve the correct angle You can remove or use both of them as needed d Loosen the nuts on the upper colla...

Page 26: ...e splines c Locate the wheel hub and brake rotor assembly and slide it onto the spindle shaft If you haven t already assembled a hub and rotor go complete step 8 and then come back d Install supplied...

Page 27: ...CB 1912496 and insert it into the brake caliper c Install the caliper onto the portal box between the new caliper bracket and rotor Use the supplied M10X1 25X25 bolts Position brake line banjo fitting...

Page 28: ...he trailing arm Use the provided loom clamp WL CLAMP 12 and then reuse the factory hardware from brake line guide to reattach to the factory hole in the arm 21 INSTALL RADIUS BARS a Reattach the upper...

Page 29: ...NT and then DR FRONT e Install a box end wrench on the caliper bleeder screw Attach a clean clear hose to fitting Be sure the hose fits tightly on fitting Now place the other end of the hose into a cl...

Page 30: ...pillage Keep a shop rag handy for any spills d On the lower backside of the portal mount is an opening for the portal box fill plug It is always toward the front of the vehicle Remove the fill plug wi...

Page 31: ...pproximately 10 25 4cm from the floor or as close to the hub axle center line as possible NOTE It is important the height of both marks be equally positioned to get an accurate measurement c In the Fr...

Page 32: ...lbs 26 INSTALL WARNING DECALS NOTICE TO DEALER INSTALLER AND VEHICLE OWNER Any vehicle equipped with a portal gear lift must have the enclosed four 4 Warning to Driver decals 1 GL 13 01 1 GL 13 02 1...

Page 33: ...al kit must be purchased from HIGH LIFTER or warranty will be voided For safety reasons it is important that the proper fastener grade thread engagement and torque specification be followed to prevent...

Page 34: ...______________________________ Place of Purchase ______________________________________________________________________ Date of Purchase _______________________________________________________________...

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