THUMPER FAB TF011601 Polaris or Ranger Headache Rack Instruction Manual
- June 12, 2024
- THUMPER FAB
Table of Contents
THUMPER FAB TF011601 Polaris or Ranger Headache Rack
PARTS
| REF | QTY | HARDWARE |
|---|---|---|
| 1 | 1 | Headache Rack |
| 2 | 1 | Accent Panel |
| 3 | 1 | Winch |
Hardware Kit
A| 2|
| Spacers
B| 8| 
| Clips
C| 16| 
| M8-1.25 x 25mm Flange Bolts
D| 4| 
| M6-1.0
x 20mm Flange Bolts
E| 4| 
| M6
Lock Washers
F| 3| 
|
1/4”-20 x 3/4” Socket Cap Screw
G| 3| 
|
1/4”-20 Lock Nut
H| 2| | Zip Ties
TOOLS
- 10 mm Socket
- 13 mm Socket
- 13 mm wrench
BEFORE YOU BEGIN
If you do not feel comfortable installing your Thumper Fab HEADACHE RACK,
please see your nearest POLARIS® Dealer for installation.
INSTALLATION INSTRUCTIONS
Install Accent Panel
Fasten the accent panel to the headache rack using 8 X M8-1.25 x 25mm flange bolts (C). Tighten evenly with 13 mm socket (FIG 1).
Install Fairlead
Remove the fairlead from supplied box and slide it into place under the winch
cover plate bull bar. Use the 2 short M8x1.25 bolts, M8 lock washer, and
M8x1.25 nuts supplied in winch box along with 13mm socket and 13mm wrench to
fasten fairlead to headache rack ( FIG 2 ).
Install Winch
Run winch cable through hole in winch cover plate and through fairlead to prepare to fasten the winch to the winch base plate. Be careful not to pinch cable ( FIG 3 ).
Fasten Winch
Fasten the winch to the winch base plate 4 x M6-1.0 x 20mm flange bolts (D)
along with M6 lock washers (E) using 10mm socket ( FIG 4 ).
Clip Spacers on Rear Cage Brackets
If you do not have (OEM) full doors you will also add the spacer (A)
between the factory accessory bracket and the headache rack bracket on the
upper bracket. Attach 2 clips (B) on each factory accessory bracket on
the rear of the cage. If you have full doors these spacers (A) and the
clips (B) are not needed on the upper bracket, you will reuse the factory
nut plate ( do not use clips on the upper bracket with full doors ) (
FIG 5 ).
Install Headache Rack
Hold the headache rack in place and use the 8 X M8-1.25 x 25mm (C) flange
bolts and 13mm socket to fasten the headache rack to the upper holes in the
roll cage. Do not fully tighten until all bolts have been started. Once they
have all been started, tighten all bolts (FIG 6).
Winch Wiring
Please refer to wiring instruction contained in the winch box for complete detailed instructions for proper wiring of winch. Mount the remote switch for the winch to the accent panel ( FIG 7 ). The winch contactor can be mounted in the battery box using supplied bracket using 3 x 1/4”-20 x 3/4” socket cap screws (F) and 3 x 1/4”-20 lock nuts (G) and 2 zipties (H) ( FIG 8 ). Note: Install vehicle used was a 2021 Ranger XP 1000, wire routing may vary for different Ranger submodels.
Install Cube Lights (Optional)
Attach cube lights to the winch mount plate using the hardware provided in the
cube light box and wire using supplied harness (F IG 9).
The installation of products sold or manufactured by Thumper Fab including, but not limited to suspension components such as lift kits, control 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 specifications 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, including 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 aftermarket 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 removal 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 collision 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 passengers of the modifications performed to your vehicle prior to operation.
Insurance companies may handle coverage of a modified vehicle differently. 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).
Customer Service
Thumper Fab
5103 Elysian Fields Rd, Marshall, TX 75672
Customer Service: 903-472-0928
www.thumperfab.com
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>