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High Lifter PGL-KIT-RZRT Manual

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PGL-KIT-RZRT
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Summary of Contents for High Lifter PGL-KIT-RZRT

  • Page 1 PGL-KIT-RZRT...
  • Page 2 This risk is compounded if the riders do not wear an approved helmets and other safety gear. High Lifter urges that all approved safety gear be worn when riding an ATV and/or RUV as a driver or passenger.
  • Page 3 All claims for damaged shipments must be made within 72 hours of delivery to the point of destination. Any damage to package should be noted with carrier at the time of delivery if possible. We will not be responsible for damage claims made over 72 hours after delivery to the point of destination. PGL-KIT-RZRT...
  • Page 4 90 ft lbs Tie rod jam nut 15 ft lbs Trailing arm to backing plate bolts (1/2") 90 ft lbs Trailing arm to backing plate bolts (3/8") 40 ft lbs Alignment, front toe tolerance 1/8” to 3/16” (3.2-4.8mm) Toe Out PGL-KIT-RZRT...

  • Page 5: Front Installation

    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 PGL-KIT-RZRT...

  • Page 6: Parts Diagram

    PARTS DIAGRAM PGL-KIT-RZRT...
  • Page 7 PGL-KIT-RZRT...
  • Page 8 Take precautions to ensure the brake hose isn’t stretched or pinched. d. Retain the factory bolts & nuts. They will be reused during the installation of the bolt-on portal boxes & mounting brackets. PGL-KIT-RZRT...
  • Page 9 Remove upper ball joint pinch bolt from the knuckle (15mm). Then remove the lower ball joint nut from the knuckle. (18mm) i. Remove the knuckle and retain the factory bolts & nuts. They will be re-used later in the install process. PGL-KIT-RZRT...
  • Page 10 Slide (1) 7/16” washer onto each bolt and loosely fasten the bolts with 7/16” lock nuts. (5/8)[70 ft lbs] e. Properly position and insert the lower ball joint into the lower ball joint mounting bracket on the backing plate assembly. PGL-KIT-RZRT...
  • Page 11 If you are using forward raked arms, then insert the supplied 10mm x 1.25 x 55mm bolt and fasten with a 10mm x 1.25 lock nut. This bolt will provide more clearance. Torque front ball joint pinch bolt (15mm)[50 ft lbs] PGL-KIT-RZRT...
  • Page 12 Slide (1) 1/2” flat washer onto (3) ½ x 4 ½” bolts. Insert these bolts through the three holes shown below. Then insert (1) ½ x 4 ½” bolt into the lower caliper mount hole. This bolt does not use a washer for the front portal boxes. PGL-KIT-RZRT...
  • Page 13 4 ½” bolts. (3/4)[105 ft lbs] e. Install the tie rod end in through the top of the portal box tie rod mount bracket. Fasten the tie rod end with the factory nut. (18mm)[90 ft lbs] PGL-KIT-RZRT...
  • Page 14 (27mm)[180 ft lbs] c. Align the portal box lid cap & gasket. Use the (4) 8-32x1/2” screws and install to the portal box. [8 ft lbs] d. Slide the spindle spacer PGLC-SPINDLE-SP onto the spindle shaft. PGL-KIT-RZRT...
  • Page 15 PGLC-WSTUD-102. d. You can use a press to install the studs. You can also use large sockets as spacers to press them in. Take care not to press the studs into the threaded tapped holes for the rotor! PGL-KIT-RZRT...
  • Page 16 Apply LOCTITE (RED) to (4) 3/8-16 x 1" button head bolts (BSH381). Insert the screws through the rotor, the spacers, and then into the hub. Tighten and torque. [45 ft lbs] PGL-KIT-RZRT...
  • Page 17 Now check the camber and determine if it is positive or negative. You want to set it as close as you can to ZERO. To do this, you can visually look down the side of your UTV and use an angle locator tool. If it is good, proceed to step #7. If not, then continue following these steps. PGL-KIT-RZRT...
  • Page 18 Reconnect the upper ball joint mount bracket to the portal box. Check the camber again. If it’s correct, proceed to step #7. If not, repeat the previous step until you achieve the correct angle. NOTE: You can purchase more shims if needed PGL-KIT-RZRT...
  • Page 19 Find the master cylinder on the (DR) side. First, unplug the connector. Then disconnect the banjo bolt and brake lines from the master cylinder. Make sure to save the washers from the factory that separate the two front lines. PGL-KIT-RZRT...
  • Page 20 The factory brake line banjo bolt should be in this sequence: bolt, washer, (PA) extended length brake line, washer, (DR) brake line, and washer. f. Tighten & torque banjo bolt to master cylinder. (12mm) [50 ft lbs] PGL-KIT-RZRT...
  • Page 21 Steel wheels = [50 ft lbs] WARNING: Retighten lug nuts at eight (8) hours after any wheel change or anytime lug nuts are loosened. Failure to do so could cause wheels to come off while the vehicle is in motion. PGL-KIT-RZRT...
  • Page 22 Remove the bolts and nuts that attach the rear knuckle to the radius bars. Retain the factory bolts & nuts. They will be reused during the installation of the Portal Boxes & Mounting Brackets. (15mm) g. Remove the rear knuckle. PGL-KIT-RZRT...
  • Page 23 2) Insert a 1/2 x 1 ¼” bolt with a ½” washer. (3/4)[90 ft lbs] 3) Insert a 1/2 x 1 ¼” bolt with a ½” washer. (3/4)[90 ft lbs] 4) Insert a 3/8 x 1 ¼” bolt with a 10mm washer. (9/16)[40 ft lbs] PGL-KIT-RZRT...
  • Page 24 2) Slide a single 1/2” flat washer onto (2) ½ x 4 3/4” bolts. Insert the bolts through the bottom two holes of the rear portal box and out through the backing plate. Slide a ½” flat washer onto each bolt end and fasten each bolt with a ½” lock nut. (3/4)[105 ft lbs] PGL-KIT-RZRT...
  • Page 25 With the portal box assembly in place, double check that the factory axle shaft is properly aligned into the drive gear of the portal box. b. Apply LOCTITE 243 (Blue) to the supplied M18 machined nut with shoulder PGLC-AXNUT and tighten & torque onto the drive shaft axle. (27mm)[180 ft lbs] PGL-KIT-RZRT...
  • Page 26 Install supplied 3/4 SAE grade 8 flat washer and tighten the 3/4-16 castle nut. (1-1/16” - 27mm)[Minimum 120 ft lbs]. Tighten the slotted nut further if needed to align grooves with holes in spindle for cotter pin. Then install supplied large cotter pin. Both ends of the cotter pin must be folded. PGL-KIT-RZRT...
  • Page 27 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. PGL-KIT-RZRT...
  • Page 28 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 radius bar using the factory washer and lock nut. (18mm)[90 ft lbs] PGL-KIT-RZRT...
  • Page 29 Repeat these steps until clean fluid appears in the bleeder hose and all the air has been purged... Close bleeder screw, pump brakes, hold pressure, open bleeder, close bleeder, release foot pedal, check master cylinder. PGL-KIT-RZRT...
  • Page 30 Remove all jacks, jack stands and other devices used to lift and hold the vehicle. c. With the suspension supporting vehicle weight, torque the wheel lug nuts using a “X” tightening pattern. Aluminum wheels = [90 ft lbs] Steel wheels = [50 ft lbs] PGL-KIT-RZRT...

  • Page 31: Front Alignment

    (A) is wider than the rear measurement (B). g. If the toe alignment is incorrect, measure the distance between vehicle center and each wheel (use the chalk mark as wheel center). This will tell you which tie rod needs adjusting. PGL-KIT-RZRT...
  • Page 32 Replacement Warning Decals are available FREE on request. These instructions are to be kept with the vehicle registration. WARRANTY IS VOIDED unless the official decals are in place. PGL-KIT-RZRT...
  • Page 33 Any parts used to repair a portal 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 parts from failing.
  • Page 34 High Lifter Products Warranty Claim Name: _______________________________________________________________________________ Address: _____________________________________________________________________________ Phone Number: _______________________________________________________________________ E-Mail Address: ________________________________________________________________________ Portal Gear Kit Product Number: __________________________________________________________ Place of Purchase: ______________________________________________________________________ Date of Purchase: ______________________________________________________________________ Reason for Return: _____________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Return Merchandise Authorization (RMA) Number: ________________________________...