THUMPER FAB TF011902, TF011903 Ranger XP1000 Bed Rack Instruction Manual

THUMPER FAB TF011902, TF011903 Ranger XP1000 Bed Rack

Product Information

Ranger XP1000 Bed Rack

The Ranger XP1000 Bed Rack is a product from Thumper Fab that is designed for use with Polaris Ranger XP1000 vehicles. The product comes in two SKUs: TF011902 and TF011903. The bed rack is made up of various components, including rear and front columns, lower and upper main rails, sway support, rear brace, upper rack, and upper rack accent panel. The product also comes with a hardware kit that includes bolts, nuts, washers, and lock & ride plastic retainers.

Installation Instructions

Before installing the bed rack, ensure that you have all the necessary tools and materials. The installation process involves assembling each side of the bed rack and then securing it to the Ranger vehicle. Here are the detailed installation instructions:

Assemble Each Side

1. Separate and stage materials for the driver and passenger’s side on a table.

Hand Tightens Hardware for the Side Panels of the Bed Rack:

1. Assemble lower main rail – DR (6), rear column -DR (1), front column DR (3), middle rail – DR (8), and upper main rail – DR (10).
2. Using 16 X M8-1.25 x 55mm flange bolts (H), 12 X M8-1.25 x 20mm flange bolts (I) & 28 X M8-1.25 x flange lock nuts (J), loosely attach the side panel of the bed rack.

Install Kolpin Lock & Ride Mounting Kit to Corners of Side Panel:

1. Leave the front lower bolts out.
2. Loosely install Kolpin Lock & Ride Mounts (G) to the bottom four corners of the assembled side panel then attach the side panels to the Ranger bed at all four corners.

Insert Kolpin Lock & Ride Mounts in Corners and Tighten:

1. Insert the Kolpin Lock & Ride Mounts (G) in the four corners of the bed, and tighten all (they will expand to fit the factory holes when tightened).
2. Once Lock & Ride Mounts fit securely, raise the bed for easier fastening of the front hardware.

Secure Lock & Ride Plastic Retainers in Front Corners of Bed:

1. Using the 7/16 socket & 7/16 wrench, tighten in this order: 1 X 1/4-20 x 6.0 SS hex bolt (C), 1 X plastic retainer (install from the bottom) (F), 2 X 1/4 x 1 washer (E) (one under the head of the screw and one after the retainer), & 1 X 1/4 x 20 flanged lock nuts (D) tighten on both front corners of the bed.
2. Once front 2 mounting fasteners are hand tight, lower bed for remainder of the installation.

PARTS

HARDWARE

Nuts

C| 2| 1/4-20 x 6.00” SS Hex Bolts
D| 2| 1/4” x 20 Flanged Lock Nuts
E| 4| 1/4” x 1 Fender Washers
F| 2| Lock & Ride Plastic Retainers
G| 4| Lock & Ride Mounts
H| 16| M8-1.25 x 55mm Flange Bolts
I| 20| M8-1.25 x 20mm Flange Bolts
J| 36| M8-1.25 Flanged Lock Nuts
K| 2| Cube Light Covers
L| 8| 1/4-20 x 1/2 SS Button Heads
M| 8| 1/4 x 1/2 SS Flat Washers
N| 8| 1/4 x 20 SS Lock Nuts

BEFORE YOU BEGIN

If you do not feel comfortable installing your Thumper Fab Bed Rack please see your nearest Polaris® Dealer for installation.

INSTALLATION INSTRUCTIONS

Assemble Each Side
These instructions will be followed for drivers and passengers side, they can be completed consecutively or individually. Separate and stage materials, this will be easiest on a table (FIG 1).

TOOLS

• 10mm Socket
• 13mm Socket
• 7/16” Socket
• 10mm Wrench
• 13mm Wrench
• 7/16” Wrench
• Ratchet
• Rubber Mallet

Hand Tighten Hardware for the Side Panels of Bed Rack

• Assemble lower main rail – DR (6), rear column -DR (1), front column – DR (3), middle rail – DR (8) and upper main rail – DR (10). Using 16 X M8-1.25 x 55mm flange bolts (H), 12 X M8-1.25 x 20mm flange bolts (I) & 28 X M8-1.25 x flange lock nuts (J), loosely attach side panel of bed rack (FIG 2).

Install Kolpin Lock & Ride Mounting Kit to Corners of Side Panel

• Leave the front lower bolts out. Loosely install Kolpin Lock & Ride Mounts (G) to the bottom four corners of the assembled side panel then attach the side panels to the Ranger bed at all four corners (FIG 3).

Insert Kolpin Lock & Ride Mounts in Corners and Tighten

• Insert the Kolpin Lock & Ride Mounts (G) in the four corners of the bed, tighten all (they will expand to fit the factory holes when tightened). Once Lock & Ride Mounts fit securely, raise the bed for easier fastening of the front hardware (FIG 4).

Secure Lock & Ride Plastic Retainers in Front Corners of Bed

• Using the 7/16” socket & 7/16” wrench, tighten in this order: 1 X 1/4-20 x 6.0 SS hex bolt (C), 1 X plastic retainer (install from the bottom) (F), 2 X 1/4” x 1 washers (E) (one under the head of the screw and one after the retainer), & 1 X 1/4” x 20 flanged lock nuts (D) tighten on both front corners of the bed. Once front 2 mounting fasteners are hand tight, lower bed for remainder of install (FIG 5).

Remove the Two Middle Rail Screws to Fasten Rear Brace

• Remove the 4 X M8-1.25 x 55mm Flange Bolts (H) and 4 X M8-1.25 flange lock nuts (J) to be able to install the rear brace (14) (FIG 6).

Fasten Rear Brace

• Using the rear brace (14), connect both sides using 4 X M8-1.25 x 55mm flange bolts (H) and 4 X M8-1.25 flange lock nuts (J) hand tight-en (FIG 7).

Install Upper Basket

• Place the upper rack – FRONT (16) on top of the bed rack towards the front of the unit. Secure into place using 2 X M8-1.25 x 20mm flange bolts (I) & 2 X M8-1.25 flange lock nuts (J). Next, place the upper rack – REAR (15) behind the upper rack – FRONT (16) using 2 X M8-1.25 x 20mm flange bolts (I) & 2 X M8-1.25 flange lock nuts (J)(FIG 15). Once hand tight install sway supports (12 & 13) using 4 X M8-1.25 x 20mm flange bolts (I) and 4 X M8-1.25 flange lock nut (J) (FIG 16).
• Fasten front and rear racks from the underside using 3 X M6-1.0 x 16mm flange bolts (A) and 3 X M6-1.0 flange lock nuts (B). Using 10mm socket and 10mm wrench to fasten the upper rack connection brackets (18) and the upper rack accent panels (17) with 8 X M6-1.0 x 16mm flange bolts (A) and M6-1.0 lock nuts (B). Tighten all bed rack bolts using 13mm socket and 13mm wrench (FIG 17).

ACCESSORIES

LIGHT KIT (INSTRUCTIONS IN BOX)
1| 2| Cube Lights
2| 2| 6” Light Bar
3| 1| Rack Harness
4| 1| Bike Harness
SPARE TIRE CARRIER
5| 1| Tire Mount Assembly
6| 1| Frame Mount Assembly
7| 1| Tire Adjuster Mount Brace
8| 1| Tire Height Adjuster
9| 1| Tire Diameter Adjuster Mount
REAR DOOR
10| 1| Rear Door
11| 1| Latch A
12| 1| Latch B
13| 1| Latch C
14| 1| Mount Hinge
TOOLS – Rear Door

•     9/16” Socket

•     10mm Socket

•     13mm Socket

•     10mm Wrench

•     13mm Wrench

•     7/8” Wrench

•     9/16” Wrench

•     11/16” Wrench

|
REF| QTY| DESCRIPTION
---|---|---
FOR OPTIONAL SPARE TIRE CARRIER
A| 16| M8-1.25 x 20mm Flange Bolt
B| 16| M8-1.25 Flange Lock Nut
C| 2| M12-1.5 Hex Cap Screw
D| 2| M12-1.5 Wheel Nut
E| 4| M8 Flat Washer
FOR OPTIONAL REAR DOOR
F| 2| M6-1.0 x 16mm Flange Bolts
G| 2| M6-1.0 Flange Lock Nuts
H| 6| M8-1.25 20mm Flange Bolts
I| 6| M8-1.25 Flanged Lock Nuts
J| 2| 3/8”-24 Hiem Joints
K| 2| 3/8”-24 Jam Nuts
L| 2| 3/8”-16 x 1-1/2” Flange Head
M| 2| 3/8”-16 Lock Nut
N| 1| Retractable Spring Plunger
O| 2| 1 1/4” Tubing Plugs

Rear Door

ACCESSORY INSTALLATION INSTRUCTIONS

Optional Spare Tire Carrier Install
Using 8 X M8-1.25 x 20mm flange bolts (A) and 8 X M8-1.25 flange lock nuts (B) assemble the tire adjuster mount brace (7), tire height adjuster (8), and tire diameter adjuster mount (9) (FIG 17).

Using the remaining 8 X M8-1.25 x 20mm flange bolts (A), and 8 X M8-1.25 flange lock nuts (B) to fasten the frame mount assembly (6) to the tire mount assembly (5). Use the 2 X M12-1.5 hex cap screws (C) and 2 X M12-1.5 wheel nuts (D) to attach tire to mount assembly (5)(FIG 18).

Optional Rear Door
Remove the 2 rear middle rail bolts on both sides. Connect latch A (11), latch B (12) & latch C (13) with slots centered use 2 X M6-1.0 x 16mm flange bolts (A) and 2 X M6-1.0 lock nuts (B) and 10mm socket and 10mm wrench. Insert the new piece (latch) in to the driver side rear column (1), loosley fasten using 4 X M8-1.25 x 20mm flange bolts (H) and M8-1.25 flange lock nuts (I) (FIG 19).

Secure Hiem Joints
Thread 2 X 3/8”-24 hiem joints (J) and 2 X 3/8”-24 jam nuts (K) into weldnuts provided in mount hinge (14). Do Not Tighten!! Using the 6 X M8-1.25 x 20mm flange bolts (H) and 6 X M8-1.25 flange lock nuts (I) fasten the mount hinge (14) to the passenger rear column using a 13mm socket and 13 mm wrench (FIG 18).

Installation of Rear Door
Place the rear door (10) into place on the Hiem joint and test fit door swinging path using 2 X 3/8-16 x 1-1/2” flange head bolts (L) and 2
X 3/8-16 lock nuts (M). Adjustment of hiem joints (J) will need to be performed to align the retractable spring plunger (N) with the latch assembly, this may take several attempts back out lower hiem and screw in upper hiem to adjust door height at latch (driver side) (FIG 19).

Retractable Spring Plunger
Install the retractable spring plunger (N). Once door is aligned properly using adjustment of hiem joints (J) the door should easily swing and close properly. Tighten all remaining hardware and install 2 X plastic tub-ing plugs in the end of the driver side door (O) using rubber mallet (FIG 20 & 21).

If you’re enjoying your Ranger Bed Rack, check out these other Thumpin’ accessories!

• The installation of products sold or manufactured by Thumper Fab in-cluding, but not limited to suspension components such as lift kits, con-trol arms, frame stiffener kits, roofs, roll cages, and tires that exceed the original specifications for the vehicle, may change the vehicle’s center of gravity and handling characteristics both on- and off-road. You are aware that the installation of tires that are larger than original vehicle specifi-cations may reduce the effectiveness of the braking system. Use of these products may place added stress to the original factory vehicle components which could cause them to weaken or possibly fail.

• Products sold or manufactured by Thumper Fab are intended for off-road use only. Operation of a vehicle modified with these products on a road could result in serious bodily injury or death, and such operation may violate the laws of your state or municipality. You agree to operate your vehicle exclusively in the manner intended by the vehicle manufacturer. You agree that failure to safely and reasonably operate your vehicle could result in serious bodily injury or death, and that, as a result of installation of this product(s) to your vehicle, extreme care must be taken to prevent vehicle rollover or loss of control, which may be more likely to occur as a result of said modifications. You will avoid unsafe maneuvers, includ-ing sudden sharp turns or other abrupt maneuvers, which could make a vehicular accident more likely. You understand that Thumper Fab is not responsible or liable for any damages or any injuries to yourself or your passengers that could occur upon possible accidents due to driver error, incorrect installations, bad judgment, incompatibility with other after-market accessories, or natural disasters to the fullest extent allowable by law. You will have all vehicle occupants fasten seatbelts, if equipped, and wear proper safety equipment, such as

• DOT approved helmet and eye protection prior to operating the vehicle. You understand and acknowledge that failure to wear proper safety equipment may increase the risk of serious bodily injury or death to yourself and any passengers.
  Proper installation of products sold or manufactured by Thumper Fab requires knowledge of the factory recommended procedures for remov-al and installation of original equipment components. Installation of these products without proper knowledge and experience may affect the performance of these components and the safety of the vehicle and cause serious bodily injury or death.

• It is strongly recommended that a certified mechanic familiar with the installation of similar components perform the product(s) installation.

• Prior to installing any products sold or manufactured by Thumper Fab, you will perform or cause
  to be performed an inspection of their vehicle to confirm its condition is suitable for the installation of these products. A proper inspection of the vehicle includes confirmation that the vehicle has not been in a collision and is free of corrosion. If the vehicle is suspected to have been in a col-lision or misused, or is otherwise unsuitable for modification, you will not install the product(s). You will continue to inspect the vehicle prior to each use to confirm its condition is suitable for its intended use, and you acknowledge that the failure to do so may result in serious bodily injury or death, as well as damage to the vehicle itself.

• You will install any warning labels provided with the product so it may be prominently seen by yourself and all passengers. You will notify all passen-gers of the modifications performed to your vehicle prior to operation.

• Insurance companies may handle coverage of a modified vehicle different-ly. Please check with your insurance carrier prior to modifying the vehicle to ensure your coverage remains sufficient.

• Installation of this product(s) may void your vehicle warranty. If this is a concern, please check with the manufacturer or dealer before purchase or installation of this product(s).

• Thumper Fab
  

• 5103 Elysian Fields Rd, Marshall, TX 75672 Customer Service: 903-472-0928
  

• www.thumperfab.com

Documents / Resources

| THUMPER FAB TF011902, TF011903 Ranger XP1000 Bed Rack [pdf] Instruction Manual
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References

• Thumper Fab - UTV Accessories

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