SSV KIT - UPPER SOFT DOOR PANELS
| Product: | Side-by-side |
| Project no: |
487802585_rev1
|
| Instruction Sheet P/N: | 487802585 |
| Revision no: |
1
|
| Revision date: |
November, 2018
|
| Item covered: | UPPER SOFT DOOR PANELS |
The following symbols may be used in this document.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
NOTICE Indicates an instruction which, if not followed, could severely damage vehicle components or other property.
- For safety reasons, this kit must be installed by an authorized BRP dealer.
- This kit is designed for specific applicable models only (authorized BRP dealers will confirm model(s)). It is not recommended for units other than the one (those) for which it was sold.
- If the installation of the kit requires a template, ensure template is to scale.
- Should removal of a locking device (e.g. lock tabs, self-locking fasteners, etc.) be required when undergoing disassembly/assembly, always replace with a new one.
- Torque wrench tightening specifications must strictly be adhered to.
- Always wear EYE PROTECTION AND APPROPRIATE GLOVES when using power tools.
- Unless otherwise specified, engine must be OFF when performing any operation on the vehicle.
- Always be aware of parts that can move, such as wheels, transmission components, etc.
- This product does not provide additional roll over protection
Some important safety information and/or operating instructions dedicated to the end usermight be included in this instruction sheet. Make sure to give the kit part number as well as the instruction sheet included with this kit to the customer. Verify that the customer has access to all the information required for proper use of the accessory.
NOTE: USE TIGHTENING TORQUES IN THE FOLLOWING TABLE IF NOT OTHERWISE SPECIFIED.
| GRADE | ||||
| 5.8 | 8.8 | 10.9 | 12.9 | |
| M4 | 1.8 ± 0.2 N•m (16 ± 2 lbf•in) | 2.8 ± 0.2 N•m (25 ± 2 lbf•in) | 3.8 ± 0.2 N•m (34 ± 2 lbf•in) | 4.5 ± 0.5 N•m (40 ± 4 lbf•in) |
| M5 | 3.3 ± 0.2 N•m (29 ± 2 lbf•in) | 5 ± 0.5 N•m (44 ± 4 lbf•in) | 7.8 ± 0.7 N•m (69 ± 6 lbf•in) | 9 ± 1 N•m (80 ± 9 lbf•in) |
| M6 | 7.5 ± 1 N•m (66 ± 9 lbf•in) | 10 ± 2 N•m (89 ± 18 lbf•in) | 12.8 ± 2.2 N•m (113 ± 19 lbf•in) | 16 ± 2 N•m (142 ± 18 lbf•in) |
| M8 | 15.3 ± 1.7 N•m (135 ± 15 lbf•in) | 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) | 31.5 ± 3.5 N•m (23 ± 3 lbf•ft) | 40 ± 5 N•m (30 ± 4 lbf•ft) |
| M10 | 29 ± 3 N•m (21 ± 2 lbf•ft) | 48 ± 6 N•m (35 ± 4 lbf•ft) | 61 ± 9 N•m (45 ± 7 lbf•ft) | 73 ± 7 N•m (54 ± 5 lbf•ft) |
| M12 | 52 ± 6 N•m (38 ± 4 lbf•ft) | 85 ± 10 N•m (63 ± 7 lbf•ft) | 105 ± 15 N•m (77 ± 11 lbf•ft) | 128 ± 17 N•m (94 ± 13 lbf•ft) |
| M14 | 85 ± 10 N•m (63 ± 7 lbf•ft) | 135 ± 15 N•m (100 ± 11 lbf•ft) | 170 ± 20 N•m (125 ± 15 lbf•ft) | 200 ± 25 N•m (148 ± 18 lbf•ft) |
| M16 | 126 ± 14 N•m (93 ± 10 lbf•ft) | 205 ± 25 N•m (151 ± 18 lbf•ft) | 255 ± 30 N•m (188 ± 22 lbf•ft) | 305 ± 35 N•m (225 ± 26 lbf•ft) |
| M18 | 170 ± 20 N•m (125 ± 15 lbf•ft) | 273 ± 32 N•m (201 ± 24 lbf•ft) | 330 ± 25 N•m (243 ± 18 lbf•ft) | 413 ± 47 N•m (305 ± 35 lbf•ft) |
NOTE: The illustrations/photos in this document show typical construction of the different assemblies and may not reproduce the full detail or exact shape of the parts; however, they represent parts that have the same or similar functions. Left hand side shown repeat for other side.
Installation time is approximately 2.0 hours.
USE AND CARE INFORMATION:
- Completely read and understand the instructions before installing this accessory.
- To clean, sponge with mild soap and cold water, rinse with a hose and allow it to drip-dry.
- Do not machine wash or dry.
- Use mild detergent to remove stubborn stains.
- When not in use, the window roll up webbing strap can be snapped back to itself.
- When window is open, use the window roll up webbing to attach the window outside of door.
NOTICE The window could be damaged by the latch if it is hanging inside when closing door.
The zipper should be cleaned using a toothbrush with soap and water and rinsed as needed to keep it free of dust and dirt. Once the zipper is cleaned, the teeth should be lubricated using beeswax.
To reduce the risk of severe injuries or death, read the safety labels and follow these rules. Upper soft door panels are not intended to retain and/or protect occupants.
ALWAYS
ALWAYS
- Fasten your seat belt.
- Keep your entire body inside the cockpit.
- Latch the door before riding.
- Transport this vehicle facing forward.
NEVER
NEVER
- Put your elbow on the door while riding.
- Exceed 120 km/h (75 MPH) while transporting this vehicle.
NOTICE This accessory will create the need for more frequent air cleaner maintenance. Service the air cleaner daily when operating in dusty conditions.
PARTS TO BE INSTALLED
Upper soft door panels
| ITEM | DESCRIPTION | QTY | PART NUMBERS |
|---|---|---|---|
| 1 | LHS Front door | 1 | In service kit 715005167 |
| 2 | RHS Front door | 1 | In service kit 715005168 |
| 3 | LHS Front hinge bracket | 1 | In service kit 715005167 |
| 4 | RHS Front hinge bracket | 1 | In service kit 715005168 |
| 5 | Rear receiving bracket | 2 | In service kits 715005167 / 715005168 |
| 6 | Front receiving bracket | 2 | In service kits 715005167 / 715005168 |
| 7 | M8 flanged nut | 4 | In service kit 715005169 |
| 8 | M6 flanged nut | 6 | In service kit 715005169 |
| 9 | M6 Rivet nut | 2 | In service kit 715005169 |
| 10 | Hair pin #4 | 8 | In service kit 715005169 |
| 11 | M8 x 25mm Torx screw | 8 | In service kit 715005169 |
| 12 | M8 x 50mm Torx screw | 4 | In service kit 715005169 |
| 13 | M8 plastic insert | 4 | In service kit 715005169 |
| 14 | M6 x 20mm flanged bolt | 4 | In service kit 715005169 |
| 15 | .25” x 1.25” Clevis pin | 2 | In service kit 715005169 |
| 16 | M8 fender washer black | 4 | In service kit 715005169 |
| 17 | Vibratite | 1 | In service kit 715005169 |
| 18 | CAN-AM decal | 1 | 704904566 |
| 19 | 1” x 1.88” SA hook | 2 | In service kit 715005169 |
| 20 | 1” x 3.63” SA hook | 2 | In service kit 715005169 |
| 21 | M6x1x20mm Torx screw w/ nylon patch | 12 | In service kit 715005169 |
AVAILABLE SERVICE KITS
| ITEM | DESCRIPTION |
|---|---|
| 715005165 | Left soft panel (skin only) |
| 715005166 | Right soft panel (skin only) |
| 715005167 | Left soft panel and frame kit (including brackets and hardware) |
| 715005168 | Right soft panel and frame kit (including brackets and hardware) |
| 715005169 | Upper soft door panels hardware service kit |
NOTE: Upper soft door panels must be used in combination with a windshield / windscreen and a top.
TOOLS REQUIRED:
- Torque wrench
- 10mm wrench (open & socket)
- 1/2” [12mm] Drill bit
- 21/64” [8mm] drill bit
- Drill
- T25 Torx driver
- T30 Torx driver
- T40 Torx driver
- 13mm wrench (open or socket)
- Razor knife
- M8 hex drive
INSTRUCTIONS
Installing the Upper soft door panels
NOTE: If installing full enclosure, install upper door first and windshield second.
1. Apply Vibratite to the (4) M6 x 16mm bolts, the (8) M8x25mm bolts and the (4) M8 x 50mm bolts. Follow the instructions on the Vibratite package.
2. Remove the exterior door panel.Refer to shop manual. Discard hardware, use provided M6 hardware to re-install door panels.
3. Remove cage trim. Refer to shop manual.
4. Install M8 inserts in the top (4) holes in interior door panel with an M8 hex drive. Turn until flange contacts door surface. Do not over tighten M8 inserts. Drill (2) 8 mm (5/16 in) diameter holes at dimple. Hole should line up with boss on opposite side.
NOTICE Trying to make flange flush with door surface will break the flange.
5. Install M6 Rivet nut into hex cut out on cage, use Rivet nut tool. After installation, validate that the insert can hold torque: 7.5 ± 1 N•m (66 ± 9 lbf•in).
NOTE: To install new blind threaded insert the use of a proper installer is required (see following illustration). This tool is available from many automotive parts retailers or on the web.
6. Mark the hole centers for door front pin in the door panel using provided template. Drill (2) 12 mm (1/2 in) diameter holes 12 mm (1/2 in) apart. Trim out to form a slot.
NOTICE Slots must clear door attachment pins. Incorrect location could damage door and ruin plastic door panel.
7. Use (2) M8 x 25mm bolts in the top slots to mount front & rear receiving brackets finger tight only. (1) M8 x 50mm bolt in the bottom slot in front & rear brackets.
8. Use (1) M8 flanged lock nut and M8 fender washer to capture bottom bolt in front and rear brackets.
9. Install the door hinge bracket to the cage with (2) M6 x 20 bolts and (1) M6 locknut.
10. With the door open, install the door attachment pins through the door panel slot into the front and rear receiver brackets. Close the door until frame contacts cage. Do not latch door. Open window, roll up and secure using straps.
NOTICE The window could be damaged by the latch if it is hanging inside when closing door.
11. Secure door panel to vehicle door with (2) hair pins.
12. Insert the front frame hinge tube into the hinge bracket with the nut to outside of vehicle. Align the holes on the tube to the bottom holes on the bracket and insert the clevis pin. If the clevis pin is difficult to insert, rotate the small tube 180° making sure the nut stays on the outside of vehicle. Pivot the hinge tube up until it hits the back of the bracket. Insert the second clevis pin in the top holes to capture the hinge tube. Insert (2) #4 hair pins into the holes in clevis pins by reaching through the window to capture pins in bracket.
13. After the upper door is installed, loosen the bolts on hinges and striker. Adjust lower door for optimal fit with upper door. The gap between door and cage or body panel should be as uniform as possible. With door closed, use striker height to adjust door height. Tighten striker bolt. Use hinge slot to adjust door in front to rear axis. Tighten hinge bolts. Refer to shop manual.
14. Adjust the soft door back & forth to have it sit evenly in the cage. Once the door is fitted into the cage and door opens / closes without binding, tighten all nuts on front and rear receiver brackets. Re-install exterior door panels with M6 hardware provided.
| tightening torque | |
|---|---|
| M6 screws & nuts | 7.5 ± 1 N•m (66 ± 9 lbf•in) |
| M8 screws & nuts | 20 ± 1 N•m (175 ± 12 lbf•in) |
| M8 screws in threaded inserts | 16 ± 2 N•m (142 ± 18 lbf•in) |
15. Pull the front of the fabric tight to the hinge bracket. With the fabric pulled tight, mark the rubber seal where it interferes with the front door pin. Slit the rubber seal to allow the pin to pass through so the inside edge of the seal sits to the inside of the inside of the door.
16. Clean the front hinge bracket surfaces with Isopropyl alcohol and attach (1) 1” x 1.88 and (1) 1” x 3.63 self-adhesive hook. Attach the loop patches on the door to hook on hinge bracket.
WITH MIRROR
17. To attach the mirror, cut small slits in the fabric located at hole and slot on hinge bracket. Remove the upper door and burn edges of slits to stop fraying. Reinstall the upper door. Insert the bolts from the back through the bracket and slits and attach mirror. Use slot to adjust field of view. Refer to instruction sheet.
18. Reinstall all removed parts. Refer to shop manual.
Template.pdf