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PGL-KIT-RZRT 

 

5 

TOOLS REQUIRED

 

• 

Metric & standard socket assortments  

• 

Metric & standard hex key/sockets 

•

 

Torque wrench 

• 

Multi-purpose pliers  

•

 

Wire cutter/snips 

• 

Mallet (Soft face hammer)  

• 

Drift punch/pin  

• 

Water-resistant grease  

• 

DOT 4 brake fluid  

• 80w90 gear oil

 

 

FRONT INSTALLATION 

1.

 

Prepare vehicle, front 

2.

 

Removal of front brake calipers & hubs 

3.

 

Front backing plate assembly & install  

4.

 

Front portal box assembly 

5.

 

Install front portal box 

6.

 

Install front drive shaft nut with shoulder & portal box lid cap 

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 

 
REAR INSTALLATION 

13.

 

Prepare vehicle, rear 

14.

 

Removal of rear brake calipers &hubs 

15.

 

Rear portal backing plate install 

16.

 

Rear portal box assembly & install 

17.

 

Adjust rear camber 

18.

 

Install rear drive shaft jam nut, spindle spacer, & portal box lid cap 

19.

 

Install rear brake rotor assembly 

20.

 

Install rear brake hanger bracket & caliper 

21.

 

Install radius bars 

 
FINAL INSTALLATION 

22.

 

Bleed brakes 

23.

 

Fill portal boxes with oil 

24.

 

Install rear tires & wheels 

25.

 

Front alignment 

26.

 

Install warning decals 

 
 
 
 
 
 
 

Содержание PGL-KIT-RZRT

Страница 1: ...PGL KIT RZRT 1...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 7: ...PGL KIT RZRT 7...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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