Curtis Polaris Ranger 1000 Roof Kit Operating instructions

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INSTALLATION & OWNER’S MANUAL
Polaris Ranger 1000 Roof Kit
Kit p/n:1POLXP1000RF
Fits Tractor Models:
POLARIS RANGER 900, XP 900, 1000
& XP 1000
Rev. A, 06/30/2021
p/n: IM-1POLXP1000RF
(*=Not including accessories)
Approximate Installation Time *
Experienced Dealer Technician – 15 minutes
Average Dealer Technician – 20 minutes
Do-It-Yourself – 30 minutes
Approximate Product Specifications
Weight: 18 lbs.
Cab Width: 57.5 inches
The contents of this envelope are the property of the owner. Leave with the owner when installation is complete.
Register your new product quickly online at
Curtiscab.com/product-registration/
Download a digital copy of your installation
instructions online at Curtiscab.com/literature/
Curtis encourages all customers to register their
Curtis products. However, failure to do so will not
diminish right to warranty. Curtis Industries does not
sell or share your information with anyone else.
Curtis strives to continuously improve our products,
technical documentation, etc. Therefore, the
installation manual for this product may have been
updated after your product was packaged. The
latest revision of the installation manual can always
be found at the website above.
Available Options:
1. Door Kit (P/N: 1POLXP1000DR)
2. Windshield Kit (P/N: 1POLXP1000WS)
3. Rear Panel Kit (P/N: 1POLXP1000RP)
4. Front Wiper Kit (P/N 1POLXP1000WK)
5. Side View Mirrors (P/N: 9PM5)
6. Door Restraint Kit (P/N: 1POLXP1000GS)

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Curtis cabs, kits, and accessories feature an assembly of parts designed for your vehicle which require
adjustment and alignment of components to accommodate vehicle variations and provide proper weather
protection. For accurate installation, proper operation, and years of satisfaction, please read and understand the
installation and owner’s manual fully prior to installing the roof kit.
From all of us at Curtis, we thank you for choosing our product.
HELPFUL HINTS:
•Refer to parts diagram found in the service parts section of this manual to help identify parts
during the assembly process.
•To assist with the roof installation, leave all fasteners loose for later adjustment unless otherwise
specified.
•Read and understand all instructions before beginning.
•Apply a silicone sealant to seal any minor gaps that may occur due to vehicle variations.
•Before installing parts with factory installed rubber, make sure the rubber is fully installed onto the
parts for proper fit and sealing.
•Plastic washers have been supplied to provide a weather seal under the heads of some exterior
bolts. The plastic washer should be installed under each bolt head directly against the outside
cab surface. Care should be taken not to over tighten the fasteners and damage the plastic
washer.
•Make sure the areas where the supplied self-adhesive hook Velcro will be applied are clean and
dry and at room temperature for best adhesion.
driver and passenger.
Curtis accessory weights are listed in product
add additional weight to the base vehicle. All
Curtis Cabs, blades and general accessories
ADDED
WEIGHT
brochures. Deduct the accessory's total weight
from the vehicle's rated capacity and never
exceed the vehicle's rated capacity including
Exposure to Carbon Monoxide
can Cause illness, serious injury or
death. Never operate vehicle if suspicious of Carbon Monox-
ide. Inspect exhaust system for leaks monthly. Leaks can
result from loose connections, corrosion, cracks or other
damage to the exhaust manifold. If leaks are found, repair or
replace exhaust system. Do not use vehicle until repair or
replacement is complete.
•Set of Standard and Metric Sockets (3/8” Drive)
•3/8” Drive Ratchet and Long Drive Extension
•Set of Standard and Metric Open-End Wrenches
•Scissors
•Drill/Driver
WARNINGS, TIPS, & REQUIRED TOOLS
TOOLS REQUIRED:
GENERAL INFORMATION BEFORE YOU START
fastener
plastic
washer
cab
surface
California Health and Safety Proposition 65 Warning: This product may contain chemicals
known to the state of California to cause cancer and birth defects or other reproductive harm.
TABLE OF CONTENTS
WARNINGS, TIPS, & REQUIRED TOOLS...................................................... 2
KIT INSTALLATION ..................................................................................... 3-4
CARE AND MAINTENANCE........................................................................... 4
SERVICE PARTS ........................................................................................... 4
BOLT TORQUE SPECIFICATIONS ............................................................. 5-6

KIT INSTALLATION
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STEP 1: (VEHICLE PREP)
If installing multiple Curtis Polaris Ranger 1000 kits,
install in the following order.
1.Doors
2.Windshield
3.Rear Panel
4.Roof
1.1 Per figure 1.1, apply 1/2" X 9/16" foam rubber
weatherseal from the left ROPS across the
windshield mount and to the right ROPS. Cutting
the ends half way down the radius of the ROPS as
shown. Keep extra foam rubber for next step.
Tools required
Scissors
Fig. 1.1 (Apply foam rubber to windshield mount)
Fig. 2.2 (Install back screws and washers)
Install foam right above W/S Hold down bracket if installed
STEP 2: (KIT INSTALLATION)
2.1 Cut (2) pieces of 1/2" X 9/16" foam rubber
weatherseal 5-1/8” long. Per figure 2.1, install
foam rubber in the left and right corners of the
underside of the roof.
Tools required
Scissors
2.2 Position roof on top of ROPS. Per figure 2.2, install
rear flange mounting hardware. Install rubber seal
washer against roof then steel washer and screw.
Note that the M6 screws are thread forming. Keep
screws straight to avoid cross threading when
installing. Note: recommend placing roof on top
of vehicle by dropping down in place to prevent
damage to installed foam rubber on vehicle and
roof.
Hardware Used Qty
M6x1 X 20 Hex Head Flange Screw 4
1/4” X 1” Steel Fender Washer 4
1/4” X 1” Seal Washer 4
Tools required
10mm socket and wrench
Fig. 2.1 (Install Foam Rubber in Back Corners)
RIGHT
LEFT
Cut foam to
radius of ROPS
Install foam right below cut-outs if W/S
Hold down bracket is not installed

KIT INSTALLATION
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CARE AND MAINTENANCE
• Check and tighten hardware after 40 hours of operation. Periodically inspect and tighten hardware for the
remainder of the unit’s life.
1/2" SIDE BULB
WITH 1/4" GRIP
9SV-PR29-15
9SV-PR43-4
RUBBER FOAM,
1/2" X 9/16"
POLARIS RANGER 1000 ROOF KIT
SERVICE PARTS
STEP 2: (KIT INSTALLATION CONT’D)
2.3 Per figure 2.3, install front mounting hardware listed
below. Install rubber seal washer against roof then
steel washer and screw. Note that the center bolt
location may require assistance to tighten down.
Hardware Used Qty
5/16-18 X 1” Hex Head Flange Screw 3
5/16” X 1” Steel Fender Washer 3
5/16” X 1-1/4” Seal Washer 4
Tools required
1/2” socket and wrench
2.4 Roof kit installation is complete. Fig. 2.3 (Install front screws, washers & lock nuts)

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Torque Specs. for Structural Bolts
This page is for use primarily when dealing with high-strength vehicle fasteners such as ROPS hardware that hold the
structure together for safety. This page can also be used for other solid metal-to-metal joints. Do not use these high torque
values on any of the following applications involving: tubing, plastic, nylon or rubber washers, threaded inserts, etc.. See next
page regarding less critical fasteners.
The values below apply to fasteners that are dry or lubricated with normal engine oil. They do not apply if special graphited or
moly disulphide greases or other extreme pressure lubricants are used. This applies to both UNF and UNC threads.
Remember to always use the same grade or property class when replacing bolts.
IMPORTANT: on all PLATED GRADE 8 bolts, reduce torque 15% from listed bolt torque specification.
Size of Screw Property Class
Course Thread Fine Thread
Pitch (mm) Pounds Feet Newton-Meters Pitch (mm) Pounds Feet Newton-Meters
M6
5.6
1.0
3.6-5.8 4.9-7.9
-
- -
8.8 5.8-9.4 7.9-12.7 - -
10.9 7.2-10 9.8-13.6 - -
M8
5.6
1.25
7.2-14 9.8-19
1.0
12-17 16.3-23
8.8 17-22 23-29.8 19-27 25.7-36.6
10.9 20-26 27.1-35.2 22-31 29.8-42
M10
5.6
1.5
20-25 27.1-33.9
1.25
20-29 27.1-39.3
8.8 34-40 46.1-54.2 35-47 47.4-63.7
10.9 38-46 51.5-62.3 40-52 54.2-70.5
M12
5.6
1.75
28-34 37.9-46.1
1.25
31-41 42-55.6
8.8 51-59 69.1-79.9 55-68 75.9-92.1
10.9 57-66 77.2-89.4 62-75 84-101.6
M14
5.6
2.0
49-56 66.4-75.9
1.5
52-64 70.5-86.7
8.8 81-93 109.8-126 90-106 122-143.6
10.9 96-109 130.1-147.7 107-124 145-168
M16
5.6
2.0
67-77 90.8-104.3
1.5
69-83 93.6-112.5
8.8 116-130 157.2-176.2 120-138 162.6-187
10.9 129-145 174.8-196.5 140-158 189.7-214.1
M18
5.6
2.0
88-100 119.2-136
1.5
100-117 136-158.5
8.8 150-168 203.3-227.6 177-199 239.8-269.6
10.9 175-194 237.1-262.9 202-231 273.7-313
M20
5.6
2.5
108-130 146.3-176.2
1.5
132-150 178.9-203.3
8.8 186-205 252-277.8 206-242 279.1-327.9
10.9 213-249 288.6-337.4 246-289 333.3-391.6
METRIC BOLT TORQUE SPECIFICATIONS 5.6 8.8 10.9
SAE Grade No.
Bolt head identification
mark as per grade.
NOTE: Manufacturing
Marks Will Vary
TORQUE TORQUE TORQUE
Bolt Size Pounds Feet Newton-Meters Pounds Feet Newton-Meters Pounds Feet Newton-Meters
Inches Millimeters Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
1/4 6.35 5678911 12 15 12 15 16 20
5/16 7.94 10 12 14 16 17 20.5 23 28 24 29 33 39
3/8 9.53 20 23 27 31 35 42 48 57 45 54 61 73
7/16 11.11 30 35 41 47 54 64 73 87 70 84 95 114
1/2 12.70 45 52 61 70 80 96 109 130 110 132 149 179
9/16 14.29 65 75 88 102 110 132 149 179 160 192 217 260
5/8 15.88 95 105 129 142 150 180 203 244 220 264 298 358
3/4 19.05 150 185 203 251 270 324 366 439 380 456 515 618
7/8 22.23 160 200 217 271 400 480 542 651 600 720 814 976
125.40 250 300 339 406 580 696 787 944 900 1080 1220 1464
1-1/8 25.58 - - - - 800 880 1085 1193 1280 1440 1736 1953
1-1/4 31.75 - - - - 1120 1240 1519 1681 1820 2000 2468 2712
1-3/8 34.93 - - - - 1460 1680 1980 2278 2380 2720 3227 3688
1-1/2 38.10 - - - - 1940 2200 2631 2983 3160 3560 4285 4827
*Thick Nuts must be used with Grade 8 bolts
58*
2

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Tightening of Non-Structural Bolts
For light or medium duty fastening, Curtis recommends using a general industry standard of tightening until snug and then
giving an additional one quarter turn of the tool as deemed reasonable for the application (i.e.: at the installer’s discretion).
If torque values are required, the examples listed below are intended as a reasonable reference for use in the majority of
non-structural fastener applications such as: small diameter fasteners; bolts passing thru tubing, glass, plastic, nylon or
rubber washers, threaded inserts, etc.
If more than one application below applies, use the lower torque value.
FASTENER
SIZE:
FASTENER
TYPE:
WASHER
MATERIAL: APPLICATION:
TORQUE
(INCH-POUNDS)
(±5)
#10 Machine Screws - in Nylon P-Clamps 20
#10 Machine Screws - Strobe Light
(plastic base) 35
M5 Set Screws - Wiper Arm 20
1/4” Cap Nut - Windshield Wiper 20
1/4” Bolts - Tubing
(5/8” to 3/4” wide) 132
1/4” - M6 Bolts Rubber - 60
1/4” Bolts Nylon / Plastic - 72
1/4” Bolts - Factory Installed
Threaded Inserts 132
5/16” Bolts - Tubing (1” or wider) 60
5/16” Flat Head Bolts - Plastic Windshield
Hinge 79
5/16” Bolts Rubber - 120
5/16” Bolts Nylon / Plastic - 150
5/16” Ball Studs - - 150
5/16” Bolts - Factory Installed
Threaded Inserts 240
3/8” Bolts - Tubing 120
M12 Door Striker Pins - - 120