Related Manuals for HL PGL-430DI-RNG9
Summary of Contents for HL PGL-430DI-RNG9
- Page 1 (2 Seater) (4 Seater) PGL-415DI-RNG9 PGL-415DI-RNG9-1 PGL-430DI-RNG9 PGL-430DI-RNG9-1 Polaris Ranger 900 4” Dual Idler Portal Kit Parts Available For These Popular Brands and Others...
- Page 2 PRODUCT DIS CLA IMER IMPORTANT PRODUCT USE AND SAFETY INFORMATION / WARNINGS clearance. Purchasers should be aware that use of this product may increase the frequency of required injury and death on all types of terrain. It is your responsibility to always inform other operators and passengers By purchasing and installing High Lifter Products, products, user agrees that should damages occur, High Lifter Products will not be held responsible for loss of time, use, labor fees, replacement parts, or freight charges.
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Page 3: Product Dis Cla Imer
PRODUCT DIS CLA IMER THE PRODUCT IS/WILL: • Designed and intended for use on a UTV at slow speeds. • Increase the turning radius. • Increase the stopping distance when adding larger tires. • Increase and accelerate wear of factory components including bushings, bearings, ball joints, and tie rod ends. Safety Guidelines: •... - Page 5 PA RTS D IAGR A M HARDWARE, BRAKE LINE 2 seater (PGLBOX-P402-DI-B1) 4 seater (PGLBOX-P407-DI-B1) SK-VT-1 PGLC-SOCKET- PGLC-AXNUT-4 PGLC-AXNUT-2 HC812434Z 46MM M18 x 1.5 Flange & M18 x 1.5 Flange 1/4 Clear Hose 1/2” x 4- 3/4” 46mm Socket Shoulder Axle Nut Axle Nut Rear (3ft) Bolt (4ea)
- Page 6 Front INSTALL FRONT W HEELS Rem oval BECAUSE THIS IS A 2 & 4 SEATER KIT, THE PARTS AND IMAGES WILL VARY SLIGHTLY ON SOME ASPECTS OF THE INSTALL. FRONT PA S S ENGER S IDE KEEP ALL FACTORY HARDWARE. Place jack under the FRONT center of the UTV and lift until the weight is off the suspension.
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Page 7: Upper Ba Ll J Oint
Front INSTALL Rem oval BA LL J OINTS & TIE RODS TIE ROD END UPPER BA LL J OINT LOW ER BA LL J OINT Disconnect the Lower ball joint by Disconnect the tie rod from the Disconnect the Upper ball joint bolt (18mm) bolt at the... - Page 8 Front INSTALL Inst all FRONT CA LIPER BRA CKET REA R FRONT Install the 129W installed hardware caliper bracket facing the FRONT of the The installment washer washer YOU MUST DISCARD THE PRE-INSTALLED featured diagram, washer when complete. LOCK WASHER. The bolt head should Insert the washers and bolts below through the remaining (4) holes in the front portal box.
- Page 9 Front INSTALL Inst all FRONT PORTA L Loosely fasten all (4) bolts with and 1/2” lock nuts. then torque. (3/4) [105 ft lbs] TIE ROD Inst all TIE ROD END Install the tie rod end into the backing plate mount bracket. Install the bolt from underneath and fasten it on top with the factory nut;...
- Page 10 Front INSTALL Inst all ROTOR A SSEMBLY ROTOR A SSEMBLY Inst all Locate all (4) multi pattern hubs, so they can all be assembled at the same time. They are studs (12mm-1.5 stud) (4/156mm bolt pattern) NOTE: They may have oil on them to prevent corrosion.
- Page 11 Front INSTALL Inst all ROTOR A SSEMBLY Place the 1/2 spacers NOTE: COUNTER BORES ON ROTOR SHOULD BE FACING UP. tapped holes. These spacers go BETWEEN the hub and rotor. Install the rotor and secure it to the hub by applying LOCTITE (RED) to the (4) 3/8-16 x 1”...
- Page 12 Front INSTALL FRONT BRA KE LINES Rem oval LEFT DRIVER SIDE (PA) = Passenger Side (DR) = Driver Side Disconnect the factory brake lines from any retaining clips or ties that are still holding them in place. Unplug the connector. washers the master cylinder.
- Page 13 Front INSTALL FRONT BRA KE LINES Inst all RIGHT PA SS ENGER S IDE LEFT DRIVER SIDE Install the (106X) 58” FRONT RIGHT (PA) SIDE brake Install the new (106X) 50” FRONT LEFT (DR) SIDE brake line line frame and to the RIGHT (PA) side hub. frame and to the LEFT (DR) side hub.
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Page 14: Upper Control A Rm
Front INSTALL Inst all FRONT BRA KE LINES UPPER CONTROL A RM Zip Tie BRAKE LINE ROUTING Route the brake line on back side of the Zip Tie FRONT UPPER ARM. If you have FACTORY arms, secure the Zip Tie brake line to the upper arm by pulling back the factory clamps to allow the brake lines If you have AFTERMARKET arms secure the... - Page 15 Rear INSTALL Rem oval REA R W HEELS REA R PA S S ENGER S IDE KEEP ALL FACTORY HARDWARE. Place jack under the REAR center of the UTV and lift until the weight is off the suspension. Raise unit an additional 4” to accommodate portals.
- Page 16 Rear INSTALL Rem oval Inst all BUSHINGS IF YOU HAVE ACCESS TO A BLIND BEARING PULLER WE HIGHLY RECOMMEND USING THIS TOOL OVER USING A PUNCH. USING A PUNCH MAY CAUSE DAMAGE TO THE BUSHINGS. REA R KNUCKLE A S S EMB LY Remove the bolts (15mm) and nuts that attach the rear knuckle to the pivot caps and sleeves upper &...
- Page 17 Rear INSTALL Inst all REA R BA CKING PLA TE Use the factory hardware to fasten the plate to the lower control arm. (15mm) Torque [90 ft. lbs] (15mm) Torque [50 ft. lbs] Inst all BOX CA P FRONT REA R NOTE: On the REAR portal boxes, the drive gear is 1/4-20 x 3/4”...
- Page 18 Rear INSTALL Inst all REA R PORTA L Insert the washers and bolts below through the remaining (4) holes in the rear portal box. 1/2 Flat Washer 1/2 x 4-1/2” Bolt 1/2 Flat Washer 1/2 x 4-3/4” Bolt Apply water-resistant grease to the drive splines.
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Page 19: Rotor Assembly
Rear INSTALL Inst all REA R A XLE NUT apply LOCTITE (BLUE) to Align the portal box lid cap & gasket. Use the 1/4-20 the supplied M18 axle nut PGLC-AXNUT-2 and torque x 3/4” screws and install the cap to the portal box. [8 onto the drive shaft axle. -
Page 20: J Unction B Lock
Rear INSTALL Inst all REA R BRA KE LINES REA R DRIVER S IDE J UNCTION B LOCK Disconnect BOTH the junction block, located on the rear lower left side or driver side of the frame. This may require disconnecting them from any factory clamps. J UNCTION B LOCK Install the new 63”... -
Page 21: Rea R Bra Ke Lines
Rear INSTALL Inst all REA R BRA KE LINES CA LIPER Secure the caliper in place using the (2) provided M10x1.25x25 FLANGE BOLTS (2 seater) or (2) M10x1.25x25 SOCKET HEAD BOLTS (4 seater). Torque (15mm) [30 ft lbs] Ensure lbs] torque (13mm) [15 ft lbs] NOTE: the bleed off valve always goes to the TOP of the caliper. - Page 22 Br ake Lines BLEEDING BRA KES Inst all BRA KE LINES NOTE: USE DOT 4 BRAKE FLUID bleeder hose & all the air has been purged... pressure, open bleeder, close bleeder, release CAUTION: ALWAYS wear eye protection like NOTE: from entering the master cylinder. bleeder hose.
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Page 23: W Heel Insta Ll
PORTA L GEA R OIL SAE 80W-90 ALL PLUGS MUST BE LUBRICATED OR WRAPPED IN DO NOT USE AN IMPACT TOOL ON ANY PLUGS. TEFLON TAPE. PLUGS MAY NOT SIT FLUSH. DO NOT TIGHTEN TO MORE THAN 10FT LBS OF TORQUE. Ensure the vehicle is positioned securely and ‘Level’. -
Page 24: Front Wheel Alignment
FRONT W HEEL A LIGNMENT IF YOU HAVE ADJUSTBLE CONTROL ARMS, YOU MUST ADJUST THE CAMBER FIRST BEFORE PROCEEDING. DO NOT INSTALL WHEELS ONTO UTV UNTIL PROPER ALIGNMENT HAS BEEN ACHIEVED. • Straighten steering wheel INCORRECT TOE If the toe alignment is incorrect, measure the distance indicate which tie rod needs adjustment. - Page 25 H IGH LIF TER LIM ITED LIF ETIM E W A R R A N T Y High Lifter offers a Limited Lifetime Warranty to the original purchaser that our product in accordance with the manufacturer’s instructions for installation and operation of said products.
- Page 26 HIGH LIFTER PORTA L GEA R W A RRA NT Y PROGRA M performance on your ATV/UTV. LIMITED LIFETIME WARRANTY: HIGH LIFTER PRODUCTS warrants to the ORIGINAL purchaser of any Portal Gear Kit for a lifetime of protection from the date HIGH LIFTER warranty.
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