ASSAULT INDUSTRIES AI-ROOF-P-RZRXP4 Aluminum Roof Sunroof Instruction Manual
- June 17, 2024
- ASSAULT INDUSTRIES
Table of Contents
INSTALLATION INSTRUCTIONS
ROOF-P-RZRXP4: TINTED POLY ROOF WITH SPOILER
AI-ROOF-P-RZRXP4 Aluminum Roof Sunroof
Be sure to read all instructions and illustrations before starting.
From The Toolbox
Basic Hand Tools
Hex Keys
| Item | Description |
|---|---|
| A | M5 Barrel Bolt (39 pcs) |
| B | M6 Button Screw (8 pcs) |
| C | M6x20 Button/Washer (21 pcs) |
| D | M6 Nylock Nut (26 pcs) |
| E | M6x25 Bolt/Washer (2 pcs) |
| F | Thick Zinc Spacer (2 pcs) |
| G | M10x50 Hex Bolt (8pcs) |
| H | Thin Zinc Spacer (8pcs) |
| J | M10 Nylock Nut (8pcs) |
The Plan
First you will apply seal to roof brackets.
Install the 3 roof panels together.
Install the Spoiler roof brackets and spoiler.
Apply Foam/Rubber seal to top of frame.
Cut spaces in Foam seal to install clamps, and install clamps.
Install front rubber trim to front roof section.
Set roof on machine and install bolts to clamps and frame.
Install side mount brackets for roof and rear roof to frame bolts and tighten
all bolts securely.
- First , you will need to assemble a couple things before installing the roof. First, find the two Adhesive Rubber Seals. They are shaped identical to the two metal Roof Brackets that hold the two pieces of the roof together. See Fig.1a.
- Then, find the two metal Roof Brackets and orient them opposite of each other. See Fig.1b. These brackets will be used to sandwhich the two roof sections together, one bracket on top and the other up underneath.
- Then, peel one side of the paper off one of the Rubber seals and apply it to one of the Roof Brackets. And then peel and stick the other Rubber Seal to the other Roof Bracket, except make sure this bracket is mirrored opposite of the first one. Fig.1b shows both brackets laying opposite of each other and with the adhesive rubber seals already applied to one side of them.
- Now locate the two roof sections 1 & 2, and with using the two Roof Brackets, Sandwich the two Roof Sections with the Brackets as shown in Fig.2. Be sure to peel any backing from the sections off before installing the Roof Brackets, also shown in Fig.2.
- Then assemble the roof together by using the Barrel Bolts provided in your kit (item “A”). Fig.3a shows installing the Barrel Bolts with the “under side” or “inside of vehicle” side facing upward. Place the larger half of the Barrel Bolt (the one with the large cup washer) on the outside or top side of the roof, thru the hole, then install the other half (screw) into it. Snug but don’t tighten down until all 26 bolts are installed into both sections. Fig.3b shows the bolts installed looking from the “Top side” of the roof as finished.
- Fig.4 shows the two roof sections assembled with Brackets and Barrell Bolts.
- Now find the (2) Spoiler Bracket Holes on each Left and Right sides of the roof as shown in Fig.5a, and Spoiler Brackets. You will assemble the brackets to the roof using the same Barrel Bolts (item “A”) as you used joining the two roof sections together. See Fig.5b.
NOTE: Be sure you have the correct direction of the Brackets facing the front of the roof for proper fitting before installing the bolts. These should be faced with the mounting bolts towards the center of the roof and the Assault Logo upright. See Fig.6 for positioning.
-
After Spoiler Mount Brackets are mounted onto the roof, now find Spoiler Bracket 4 and bolt them to the edges of the Spoiler using the M6x20 bolts and Nylock Nuts, Items C & D as shown in Fig.7a, and tighten down.
-
Then mount the side Spoiler Bracket 1 using the M6x14 bolts and Nylock Nuts, items B & D, to Bracket 4 as shown in Fig.7b and thighten down.
-
Now you can mount the Spoiler onto the roof by also using the M6x20 bolts and Nylock Nuts, Items C & D and secure as shown in Fig.8.
-
Once the first two sections have been assembled, now you need to attach the rear panel (section-3) to the other two. There are no metal brackets to use for this joint. These simply overlap each other and are assembled together using the same Barrell Bolts (item “A”) as you used on the other two. Fig.8b shows how the panels attach together and overlap.
-
Next, install the rubber Edge Seal all along the lower front edge of the roof as shown in Fig.9a & 9b.
-
Before installing the roof onto your machine, you will need to install the clamps that hold it in place next. To do this, first install the adhesive backed rubber sealing on top of frame where roof will sit as shown in Fig.10. set the assembled roof on top the of the vehicle where it would be installed and mark on the foam stripping you applied to the top of the bars where the clamps would go according to the mounting holes in the roof. Then cut the foam leaving spaces for the clamps to fit tightly around the bars. See in Fig.10.
-
Next, install the clamps in the spaces you cut in the foam, but leave them a little loose so you can make final adjustments once all the clamps are installed and the top is placed on top. See Fig.11.
Fig.12 shows the clamp using the bolt covers and how it is used in the clamp.
-
Place Roof on top of machine and initially adjust placement. Then install the roof to the front and rear clamps using the M6x20 screws with sealing washers, item Citem C as shown in Fig.13, but leave loose until all side bracket bolts are threaded in. See Fig.13.
-
Once the front and rear clamps are attached to the roof, now you need to remove the upper factory frame bolts as shown in Fig.14 so you can install the new side brackets to mount the roof onto for the sides.
-
After removing the factory bolts, you will install two front and two rear side brackets to those locations. There are two different brackets. The ones for the Front have a slot on one side, and the other only has one hole. The slotted brackets are for the locations closest to the front of the vehicle, and the one with just a hole is for the rear location. You will install these using the hardware provided in your kit with the M10x50 Bolt item”G”item”G”, Wide Spacer item”H”item”H” and the M10 Nylock Nuts, item “J”item “J”. See Fig.15.
-
Both Front and Rear style bracket install the exact same way. First insert the M10 Bolt, item”G”, from the outside of the frame tube, thru the tube. Then slide the Wide Spacer, item”H” onto the bolt, then the Bracket you are using and then the M10 Nylock Nut, tem”J”, as shown in Fig.16. Your bracket should look like the photo in Fig.16 and also a little loose until all brackets are installed and ready for final adjustment before tightening them down with the rest of the hardware.
-
Fig.17 shows one of each of the mounting brackets, one with the slot towards the front, and one with a single hole towards the rear, looking at them from the inside, passeanger’s Side. After attaching the brackets to the frame, now install the roof to the brackets using the M6x20 Bolt with Sealing Washer, item “C”, and M6 Nylock Nut, item“D” provided in your kit, also shown in Fig.17.
NOTE: The two back corner bolts, item “E”, will use Spacers, item “F”.and Nylock Nuts, item”D”. These bolts go through the roof frame brackets, not into a clamp. See Fig.18.
-
Once all the bolts, brackets, screws and clamps are all threaded and into place, make your final placement adjustment of the roof and tighten all down securely.
-
PLEASE FEEL FREE TO CONTACT
ASSUALT INDUSTRIES FOR QUESTIONS REGARDING SPECIFICATIONS OR ANY OTHER
QUESTIONS YOU MAY HAVE. THANKS!
Liability Statement
Assault Industries® products are designed to best fit user’s ATV/UTV under
stock conditions. Adding, modifying, or fabricating any factory or aftermarket
parts will void any warranty provided by Assault Industries® and is not
recommended. Assault Industries® products could interfere with other
aftermarket accesso- ries. If user has aftermarket products on machine,
contact Assault Industries® to verify that they will work together.
Although Assault Industries® has thousands of satisfied customers, user should
be aware that installing lift kits, long travel, or suspension kits, tires,
etc. will change the ride of machine and may increase maintenance and part
wear. Operating any off-road machine while, or after, consuming alcohol and/or
drugs increases risk of bodily harm or death. No warranty or representation is
made as to this product’s ability to protect user from severe injury or death.
Assault Industries® urges operators and occupants to wear a helmet and
appropriate riding gear at all times.
By purchasing and installing Assault Industries® products, user agrees that
should damages occur, Assault Industries® will not be held responsible for
loss of time, use, labor fees, replacement parts, or freight charges. Assault
Industries®, nor any 3rd party, will not be held responsible for any direct,
indirect, inci- dental, special, or consequential damages that result from any
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the total purchase price paid for the product that gave rise to the claim.
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Any damage or problems with OEM housings, bearings, seals, or other manu-
facturers’ products will not be covered by Assault Industries®. Assault
Industries® parts and products are not warrantied if item was not installed
properly, misused, or modified.
Installing, adding, modifying, or fabricating any factory or aftermarket
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advised that laws vary depending on town, city, county, state, etc. Use of
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AI-ROOF-P-RZRXP4
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References
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