SUPERATV RZR XP4 Aluminum Roof Instruction Manual
- May 15, 2024
- SUPERATV
Table of Contents
INSTALLATION INSTRUCTIONS
Aluminum Roof: IN-ROOF-P-RZRXP4-002
RZR XP4 Aluminum Roof
What You’ll Be Doing
First you will apply seal to roof brackets.
Install the 3 roof panels together.
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.
Tighten all bolts securely.
Item| Description|
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A| Barrel Bolt| 35
B| M6x20 Button w/Washer| 9
C| M6x25 Button w/Washer| 2
D| M6 Nylock Nut| 2
E| Black Zinc Spacer| 8
F| M10x50 Hex Fl.Bolt| 2
G| 13 I.D. Black Zinc Spacer| 8
H| M10 Nylock Nut| 8
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First , you will need to assemble a couple things before installing the roof. First, find the two Adhesive Rubber Seal/Gaskets.
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 sandwich the two roof sections together, one bracket on top and the other up underneath.
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Then, peel one side of the paper off one of the Rubber Seal Gaskets and apply it to one of the Roof Brackets. Then peel and stick the other Rubber Seal Gasket 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 each metal bracket.
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Now locate roof sections 1 & 2, and with using the two Roof Brackets, Sandwich the two Roof Sections with the Brackets as shown in Fig.2.
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Then assemble the roof together by using the Barrel Bolts provided in your kit (item A). Fig.3a shows the roof sections with the brackets and barrel bolts installed.
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Place the larger half of the Barrel Bolt (the one with the large cup washer in Fig.3b) on the outside or top side of the roof, thru the hole, then install the other half (or screw also Fig.3b) into it. Snug but don’t tighten down until all 26 bolts are installed into both sections. Fig.3a also shows the bolts installed looking from the “Top side” of the roof as finished.
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Next, install the rubber Edge Seal all along the lower front edge of the roof as shown in Fig.4.
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Now you can install Panel 3, or the rear panel onto the others. This joint does not need metal brackets as the first two sections required.
These, you simply over lap each other (using a strip of the adhesive rubber seal as you used on the tops of the frame) and assemble the panels using the same Barrel Bolts, item “A”, as you did with the other panels as well. The seal will help close out weather conditions and debris when the barrel bolts are tightened down. See Fig.5. -
After assembling the panels all together, you roof should look like the one on Fig.6.
Fig.6 shows the assembled roof upside down resting on a stand.
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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.7. 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 and remove it, leaving spaces for the clamps to fit tightly around the bars. The Arrows show the basic location of the five clamps. See Fig.7.
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Now set the roof on the vehicle, See Fig.8. Next will need to install the rear corner bolts that attach the roof to the frame since these are in a fixed position.Then you can install the clamps and mounting brackets in the following steps.
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To do that you will use Items “E” – Spacer, “C” – M6x25 Bolt/ Washer and “D” – M6 Nylock Nut to attach the roof to the rear corners.
See Fig.9 & 10. -
Fig.10 shows how the bolt goes through the roof panel, then the Spacer, then the Frame Bracket and then the Nylock Nut. Do both Left and Right Sides, but leave a little loose until all roof bolts are threaded in and ready for adjustment.
(Fig.10 is shown using a clear poly roof panel instead of the Aluminum one you have, so you can see the location and order of the component placement a little better) -
Now you can install the 5 Roof Clamps, and then the 4 side Cage Brackets after that.
Looking at the Driver’s Side front roof support bar in Fig.11, line up the clamps with the holes in the roof for all 5 locations. Fig.11 shows the clamp on the bar and the bolt threaded into the clamp through the roof. -
Install the clamps using the bolts and bolt covers assembled with each clamp in your kit. Fig.12 shows the clamp mounted and also how the bolt cover is used with the clamp. Install the 2 bolts into the clamp but leave it a little loose until all clamps and roof bolts are threaded and installed.
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Next, install the roof to the clamps using the M6x20 Bolts with Sealing Washers, item “B” provided in your kit. You will use these for all 5 clamps. See Fig.13.
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Fig.14 shows the Center location of the last clamp, and it’s basic location. Again you will just find the hole in the roof and mate the clamp hole to that as well.
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Next you will install the Cage Brackets. Two on the front side area and two on the back side area. To do that, you will need to remove the upper factory frame bolts, as shown in Fig.15, so you can install the new side brackets to mount the roof to.
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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”F”, Wide Spacer item”G” and the M10 Nylock Nuts, item “H”. See Fig.16.
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Both Front and Rear style brackets install the exact same way. First insert the M10 Bolt, item”F”, from the outside of the frame tube, thru the tube. Then slide the Wide Spacer, item”G” onto the bolt, then the Bracket you are using and then the M10 Nylock Nut, item”H”, as shown in Fig.17. Your bracket should look like the photo in Fig.17 and also a little loose until all brackets and roof bolts are installed and ready for final adjustment before tightening them down with the rest of the hardware.
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Once all the bolts, brackets, screws and clamps are all threaded and into place, make your final placement adjustment of the roof and tighten them all down securely.
Liability Statement
SuperATV’s® 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 SuperATV® and is not recommended.
SuperATV’s® products could interfere with other aftermarket accessories. If
user has aftermarket products on machine, contact SuperATV*® to verify that
they will work together.
Although SuperATV® 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. SuperATV® urges operators and occupants to wear a helmet and appropriate riding gear at all times.
By purchasing and installing SuperATV® products, user agrees that should damages occur, SuperATV® will not be held responsible for loss of time, use, labor fees, replacement parts, or freight charges. SuperATV®, nor any 3rd party, will not be held responsible for any direct, indirect, incidental, special, or consequential damages that result from any product purchased from SuperATV®. The total liability of seller to user for all damages, losses, and causes of action, if any, shall not exceed the total purchase price paid for the product that gave rise to the claim.
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