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Summary of Contents for HL PGL-415DI-RNG1
- Page 1 PGL-415DI-RNG1 PGL-430DI-RNG1 Polaris Ranger 1000 4” Dual Idler Portal Kit Parts Available For These Popular Brands and Others 7455 ATKINSON DR. SHREVEPORT, LA 71129...
- Page 2 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 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 P A R T S D I A G R A M HA RDW A RE, B RA KE LINE (PGLBOX-P401-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 Axle Nut Front Axle Nut Rear...
- Page 6 Front INSTALL FRONT W HEELS Rem oval 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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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 FRONT CALIPER BRACKET Install REAR FRONT Install the 129W Each side has a pre- 1/2 x 2-1/2 1/2 x 2-1/2 installed hardware caliper bracket facing Hex bolt Hex bolt on the portal box. the FRONT of the vehicle. 1/2 lock The installment washer...
- 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 Fasten with the factory hardware.
- Page 10 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.
- Page 11 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.
- Page 12 Front INSTALL FRONT BRA KE LINES Rem oval 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.
- Page 13 Front INSTALL FRONT BRA KE LINES Inst all RIGHT PA SS ENGER S IDE LEFT DRIVER SIDE Install the 58” FRONT RIGHT brake line to the banjo Install the new 50” FRONT LEFT brake line to the banjo RIGHT (PA) side hub. LEFT (DR) side hub.
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Page 14: Ba Cking Pla Te
Front INSTALL Inst all FRONT BRA KE LINES BRAKE LINE ROUTING Route the brake line through the FRONT UPPER ARM. Install the caliper onto the portal box and secure it using factory hardware. [30 ft lbs] torque (13mm) [15 ft lbs] CA LIPER the caliper being careful not to allow debris to enter the caliper. - 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 REAR PORTAL Install 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 &...
- Page 19 Rear INSTALL Install REAR AXLE 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.
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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 caliper in place using the (2) provided M10x1.25x25 Flange 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. - 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 TAP. 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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