Trail ARMOR RZR4 800, RZR4 XP 900 Gen-X Door Debris Shields Instruction Manual
- June 3, 2024
- Trail ARMOR
Table of Contents
TRAILARMOR.COM
839 HWY 2 CORINTH, MS 38834
662-233-5700
Installation
Instructions
Trail Armor RZR4 800, RZR4 XP 900 Gen-X Door Debris Shields
TA001 BLKGX-RZR4
Warnings and Product Liability Disclaimer
This product is intended to be used as a cosmetic accessory under normal equipment operation and should not be depended upon or used as a safety device. Manufacturer assumes no liability for personal injury or equipment damage as the result of use or installation of this accessory. User assumes all risk. User should carefully read all instructions prior to installation. All Trail Armor products are designed, engineered, and fit to new vehicles and their specifications. Damage, modifications, and extreme wear may cause and require modifications to the product and/or your vehicle to insure proper fitment.
A) Locate the supplied metal debris shield hangers, hinges and bolt pack 1. Using the supplied 1/4-20 x 5/8 torx head screws and nylock nuts, install the hinges to the hanger bracket as shown in Picture 1 and 1A. Tighten fasteners loosely to allow slight movement for alignment later.
B) Install the adjustable lower tab to the hanger bracket using supplied 5/16
— 18 x 3/4 torx screw and nylock nuts. See Picture 2 for how the angle should
be oriented. Tighten these fasteners only slightly so you can adjust here
later.
C) Remove the OEM side nets from the vehicle. Remove the rear side guard tube;
discard.
D) Remove the upper seat belt mounting nut and bolt — you will reuse these in
Step E. Insert the supplied 5/16 — 18 split nut to the lower mount where the
side guard tube was removed. See Picture 3.
E) Place the assembled hinge mounting bracket into position over the seat belt
mount, start the upper bolt back into the seat belt mount and secure with the
removed nut and bolt. Check the seat belt for alignment and make sure there is
no twist in the belts. Insert the two supplied 5/16 — 18 x 3/4 torx screws
from Pack 2 into the installed split nut in the lower bracket. Tighten these
fasteners securely. See Pictures 4 and 5.
F) Remove the two bolts securing the lower rear leg of the roll cage. Insert
the door latch striker plate on top of the roll cage. Secure the door latch
striker plate with the removed bolts. From Pack 3, install the 3/8 x3/4 x 5/16
— 18 shoulder bolts, 1/4 x 1/8 washers and 5/16 — 18 nylock nuts on the pre-
drilled hole on the striker plate to serve as a latch catch. See Picture 6.
Slide U bracket from pack 2 over the front side guard tube and under the lip of the door mounting bracket. Secure with two 1/4- 20 x 1″ torx screws. See pictures 7A and B.
G) Remove the front roll cage bolts and discard — keep nylock nuts. Install the front striker plates to the outer side of the roll cage using the supplied 3/8 — 16 x 2 hex head bolts from Pack 3 and the removed OEM nylock nuts. See Picture 8. Tighten securely maintaining parallel alignment on the front edge of the brackets and roll cage. Install the 3/8 x3/4 x 5/16 — 18 shoulder bolt from Pack 3 and secure with the 5/16 — 18 nylock nut on the pre-drilled hole on the striker plate to serve as a latch catch. See Picture 9.
H) Using the fasteners from Pack 2, install the debris shield panels to the
hinges using the supplied 1/4- 20 x 1 torx head screws and nylock nuts.
Tighten securely. See Picture 10.
I ) With the debris shield panels in place, close the front and rear doors and
check the alignment with the body panels. To align, loosen the lower outer
torx bolts in the hinge bracket and the upper seat belt bolt to allow the
panels to be either picked up or pushed down to align for proper closure. When
panels are aligned, tighten all fasteners securely.
J ) Using bolt Pack 4. install the latch mounting bracket to the inside of the
latch using supplied 1 1/4″ flat socket head screws and nylock nuts as shown
in Picture 11. Once the latch mounting bracket is mounted to the latch, place
latch on inside of door panel. Insert two of the supplied 1/4-20 x 1″ torx
screws and nylock nuts through the two slotted holes into the latch bracket.
Close the door so that the handle latches over the shoulder bolt. Check
alignment. See Picture 12. Adjust if needed, then tighten. Install rotary
latch cover by simply bumping it on — it clips over the screw head. For more
secure fastening, the screw can be removed and a washer placed to the outside
of the cover. Enjoy!
A A 1/4″ — 5/16″ gap should be maintained between the latch and the strike
plate.
Revision 1
May 10. 2016
Any questions, contact Trail Armor @
662-233-5700 or
www.trailarmor.com.