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(2 Seater) (4 Seater) PGL-415DI-GEN1XP PGL-415DI-GEN1XP-1 PGL-430DI-GEN1XP PGL-430DI-GEN1XP-1 Polaris General 1000 XP 4” Dual Idler Portal Kit Lorem ipsum Parts Available For These Popular Brands and Others 7455 ATKINSON DR. SHREVEPORT, LA 71129...
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PRODUCT DISCLAIMER 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 Lorem ipsum 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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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: •...
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P A R T S D I A G R A M HA RDW A RE, B RA KE LINE 2 Seater (PGLBOX-P405-DI-B1) & 4 Seater (PGLBOX-P408-DI-B1) SK-VT-1 LOCTITE-02-B PGLC-AXNUT-4 PGLC-SOCKET- HC812434Z 46MM Blue Loctite M18 x 1.5 Flange 1/4 Clear Hose 1/2”...
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PARTS DIAG RAM FRONT BACKING PLATES PORTALS REAR BACKING PLATES (PGLBOX-P403-DI-B2) (PGLBOX-P408-DI-B3) Portal Assembly (4ea) 137Q-L 137Q-R 131o-L 131o-R PGLAB-430-DI-P401 (30%) Left Front Portal Right Front Portal Left Rear Portal Right Rear Portal PGLAB-415-DI-P401 (15%) Backing Plate (1ea) Backing Plate (1ea) Backing Plate (1ea) Backing Plate (1ea) PART NUMBER...
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Front INSTALL Rem oval FRONT W HEELS 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. Raise unit an additional 4” to accommodate portals.
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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...
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Front INSTALL FRONT CALIPER BRACKET Install REAR FRONT Install the caliper Each side has a pre- 1/2 x 2-1/2 1/2 x 2-1/2 installed hardware bracket 129W (2 Hex bolt Hex bolt on the portal box. seater) or 130A (4 seater). Bracket 1/2 lock The installment should be facing the...
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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] Inst all TIE ROD TIE ROD END Install the tie rod end into the backing plate Fasten with the factory hardware.
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Front INSTALL ROTOR ASSEMBLY Install ROTOR ASSEMBLY Install 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.
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Front INSTALL ROTOR ASSEMBLY Install NOTE: COUNTER BORES ON ROTOR SHOULD BE FACING UP. ROTOR ASSEMBLY Install Slide on the 30mm lock washer, 30mm castle nut. (46mm) [Min 120 ft lbs] Tighten the castle nut further with hole in the spindle for the cotter pin.
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Front INSTALL Rem oval FRONT BRA KE LINES LEFT 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.
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Front INSTALL Inst all FRONT BRA KE LINES RIGHT PA SS ENGER S IDE LEFT DRIVER SIDE Install the new (64Y) 56” FRONT RIGHT (PA) SIDE brake Install the factory FRONT RIGHT (PA) SIDE brake line line frame and to the RIGHT (PA) side hub. for the FRONT LEFT (DR) side.
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Front INSTALL Inst all FRONT BRA KE LINES UPPER CONTROL A RM BRAKE LINE ROUTING Route the 56” brake line along the FRONT UPPER ARM. You can secure it using the factory clamps and a #10 self tap screw. If you have aftermarket arms secure it with the supplied zip ties.
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Rear INSTALL Rem oval REA R W HEELS REA R PA S SENGER 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.
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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 and nuts (15mm) that attach the rear knuckle to the pivot caps and sleeves upper &...
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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 CORRECT INCORRECT NOTE: On the portal boxes, the drive gear splines 1/4-20 x 3/4”...
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Rear INSTALL Install REAR PORTAL washers and bolts Insert the below through the remaining (4) holes in the rear portal box. Apply water-resistant grease to the drive splines. Be sure to apply product all around the outer edge as well. Rotate the portal box ‘Up &...
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Rear INSTALL Install REAR AXLE NUT apply LOCTITE (BLUE) Align the portal box lid cap & gasket. Use the 1/4-20 to the supplied M18 x 1.5 axle nut PGLC-AXNUT-4 and x 3/4” screws and install the cap to the portal box. [8 ft lbs] torque onto the drive shaft axle.
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Rear INSTALL Inst all REA R BRA KE LINES REA R DRIVER SIDE 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. Have a container ready to collect J UNCTION B LOCK Install the new 74”...
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Rear INSTALL Inst all REA R BRA KE LINES Secure the caliper in place using the factory Bolts. Torque (15mm) [30 ft lbs] NOTE: the bleed off valve always goes to the TOP of the caliper. 5mm x 20mm 5mm x 20mm bolt, 5mm washer, and 5mm lock nut.
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Br ake Lines Inst all BLEEDING BRA KES 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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SAE 80W-90 PORTA L GEA R OIL ALL PLUGS MUST BE LUBRICATED OR WRAPPED IN DO NOT USE AN IMPACT TOOL ON ANY PLUGS. TEFLON TAP. PLUGS MAY NOT SIT FLUSH. DO NOT TIGHTEN TO MORE THAN 10FT LBS OF TORQUE. Ensure the vehicle is positioned securely and ‘Level’.
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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.
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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.
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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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