FALCON RIDGE 50-50219KIT User manual

Installation & Operations Manual : FR Flip-Up Windshield, Polaris Full-Size Pro-Fit Ranger
Part Number 50-50219KIT; 50-50837KIT
Parts List:
1. 50-50219; 50-50837 FS Ranger Windshield
2. 54-91032 Gasket
3. 54-96047 Tube Assembly
4. 54-96061 Brace Mounting Block Cover
5. 54-96064 T Handle
6. 54-96058 Shim (2)
7. 54-96080 Ball Bracket, Driver
8. 54-96081 Ball Bracket, Pass.
9. 54-96086 Gas Spring (2)
10. 54-96071 Center Retainer
11. 54-96072 Rub Plate
12. 54-96082 Strike Plate, Driver
13. 54-96083 Strike Plate, Pass.
14. 54-96085 Hinge Half, Upper (2)
15. 54-96084 Hinge Half, Lower (2)
16. 54-96055 Ball Stud Clamp (2)
17. 54-96056 FS Ranger Hardware Bag
1
Tools Needed:
•4mm, 5mm, 6mm Allen Wrenches
•10mm, 12mm, 13mm Open End Wrench
•Socket Wrench with 13mm Socket
•Small Flathead Screwdriver
Installation Information:
This product does not require any modifications to your vehicle. Please familiarize yourself with all the steps before
beginning assembly.
Falcon Ridge was established to help UTV owners adapt their vehicles for the great outdoors, Falcon Ridge
provides innovative, practical, and rugged UTV products to provide owners the confidence to work, play, or explore
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Installation Video
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14
Brace Mounting Block Small Mounting Block End Mounting Block
Parts
2
x 2 x 2 x 2
x 2
x 2
15
1
2
78
6
5
9
10 11 12 13
3
Brace Mounting Block Small Mounting Block End Mounting Block
4
16

In Tube Assembly:
M6x50 Button Head M6x45 Button Head M6x40 Button Head
M8x50 Button Head M8x30 Socket Head M8x16 Button Head
M6x30 Button Head M6x20 Socket Head M6x18 Button Head
M6 Flange Nylon Lock Nut M8 Jam Nut M6 Nylon Lock Nut
M6 Nylon Lock Nut
M8 Nylon Lock Nut M8 Rod End
x 2
x 2 x 2
x 1 x 8
x 3
x 2
x 2
x 2 x 7
x 6 x 2 x 2
x 2
x 12
Hardware
In Hardware Bag:
3

M6x40
M6x45
M6x50
7
Repeat for the other half of windshield so that the
windshield looks like this. Make sure the fasteners are
tight, but you can still rotate the ball brackets by hand
with some resistance.
Take the Tube Assembly out of its box. The tube
should be bowed with the latches curved in towards
you. Using a 4mm Allen wrench, remove all the bolts
and nuts from the mounting blocks except the M6x45
Button Head Bolt in the middle of the Brace Mounting
Block. Use picture above to remember which size bolt
goes with each mounting block.
Place the windshield down on a large flat surface with
something under it to prevent scratching. It should be
oriented with Gasket bulb-side up. This is the inside of
the windshield. There are two holes about 1.5” apart
in the middle of the top of the windshield. Make sure
they are slightly right of center.
Take the Ball Brackets and orient them on the inside
of the windshield as shown. Shown above is Ball
Bracket, Driver. Gather a 4mm allen wrench and a
10mm open wrench. Fasten an M6x18mm Button
Head Bolt through top hole in each ball bracket with a
M6 Flange Nylon Insert Lock Nut on the inside of the
windshield
.
Leave this middle
bolt fastened
1 2
3 4
4
..

Place the Tube assembly on the inside of the
windshield with the pockets for captive nuts in each of
the mounting blocks facing upwards.
Insert two M6x45 Button Head Bolts through the
windshield, and then through the Brace Mounting
Block. Put the outer two M6 Nylon Lock Nuts in their
captive pockets to fasten until just a few threads
engage. At this point just tighten by hand or finger-
tight using a 4mm Allen wrench.
Use a M6x40mm Button Head Bolt and a M6 Nylon
Lock Nut to repeat this process for each Small
Mounting Block. The hole alignment of the mounting
blocks to the holes in the windshield can be adjusted
at any time by rotating the tube within the mounting
blocks.Because of this, it is important to leave all
fasteners loose during steps 6-9.
Check the alignment on the End Mounting Blocks and
rotate the tube if needed. Now gently flex the
windshield towards the tube so that you can insert a
M6x50 Button Head Bolt through the other side of the
windshield, through the bottom hole of the Ball
Bracket, and then through the End Mounting Block.
Use an M6 Nylon Lock Nut in the captive pocket to
fasten the bolt. Only engage about 2-3 threads.
Repeat for other side.
5 6
7 8
5
..

There is a gap for the Shim to be snapped in place
over the M6x50mm Button Head Bolt in between the
End Mounting Block and the Ball Bracket. Insert the
shims in this gap in each side by snapping in from
the bottom side of the windshield. Now, working from
the middle out, tighten all bolts along the tube
assembly except the middle bolt of the Brace
Mounting Block
Remove the two M8 ball studs from each Gas Spring.
There will be 4 total ball studs. Do this by prying up
the metal retaining clip with a small flat blade
screwdriver and pulling the ball stud out. Once the ball
stud has been removed make sure the retaining clip is
back in place.
910
Install one Ball Stud onto each Ball Bracket using an
M8 Nylon Insert Lock Nut. Orient the Ball to face
inwards towards the middle of the windshield, and
fully tighten using 12mm and 13mm open end
wrenches.
11
6
Install the T Handle onto the cylinder with the
M8x30mm Socket Head Bolt. You will need a 6mm
hex key.
12

Use an M6x20mm Socket Head Bolt and a M6 Flange
Lock Nut to attach the Strike Plate on each side of the
vehicle. This step can be a little tricky. Insert the
M6x20mm Socket Head Bolt through the Strike Plate
and the hole in the welded tab while using the open
end of a 10mm wrench to hold the flange nut in place.
Once in place use a 5mm hex key to turn the socket
head bolt. Make sure the Strike Plate stays aligned as
shown. Repeat for the other side. If you drop a nut
there are two extra in the hardware bag.
Shown is the Strike Plate, Pass. Orient the part as
shown. Gather a 10mm open-ended wrench and a
5mm hex key.
15 16
7
Now install the Center Retainer on the inside of the
windshield using 2 -M6x30 Button Head Bolts and 2 -
M6 Nylon Lock Nuts.
14
Now attach each Hinge Half, Lower to the outer side
of the windshield with the angle coming away from the
polycarbonate. Fasten loosely with 4 –M8x16mm
Button Head Bolts and 4 –M8 Nylon Insert Lock Nuts.
The bolt heads should be on the metal side and the
nuts on the inside of the windshield
13
15
10
13

Thread one M8 Ball Stud into each Ball Stud Clamp Attach the Ball Stud Clamp to the vehicle frame by
loosening it’s two M8x30 Socket Head Bolts until able
to fit clamp over the tubing. Space the Ball Stud
Clamp from the Strike Plate so that its bottom edge is
12.5 inches away from the top edge of the strike plate.
This will position the ball stud clamps properly for gas
spring installation later. Tighten the M8x30 bolts very
tight!
Thread one M8 Jam Nut onto each Rod End until the
nut can go no further
Thread each M8 Rod End into the Hinge Half, Upper
as shown. This is the left upper hinge assembly.
Mirror and repeat for the right side.
17 18
19 20
8

Use a 5mm hex and a 13mm socket wrench to loosely
fasten two M8x16mm button head bolts and two M8
Nylon Lock Nuts for each Hinge Half, Upper on each
side of the vehicle. Driver side shown
Line up the holes in each side of the top hinges and
insert the M8x50 button head bolt first through the
Rod End and then through the Hinge Half, Lower Use
the M8 Nylon Lock Nuts to secure the bolt. Mirror and
repeat on other side. Tighten both sides. The
windshield can be horizontally aligned by tightening or
loosening these bolts on each side Ensure the Hinge
Half, Upper is located on the outside of the Hinge
Half, Lower when installed. As seen above.
Shown above is both assembled Hinge Halves, Upper
and their orientations on the frame of the vehicle.
Taking care to keep the Center Retainer under the
header panel, place the windshield on the frame of
vehicle.
21 22
23 24
9

Now that both strikers are engaged in the Strike
Plates, by loosening the two set screws shown above
in the Brace Mounting Block the cable length can be
changed so that the strikers bottom out in the Strike
Plates without having any excess length that would
make closing the windshield difficult. If there was not
enough length originally, when you loosen the screws
above, the strikers should then bottom out in the
Strike Plates (you may have to compress the gasket
near the strike plates by hand to facilitate this) Pull on
the cut end of the cable to remove any slack and then
re-tighten the screw. Repeat for other cable.
Press the bottom corners of the windshield in gently to
latch the strikers in the Strike Plates.
*do not slam the
windshield closed yet *
it isn’t aligned yet and it may
damage the End Blocks and/or Strike Plates. Once
both strikers are latched in the Strike Plates you can
move to the next step.
25 26
27
10
Twist the T Handle to open the windshield and lift it
until it is parallel with the ground. Have a helper (or
stick) hold the windshield in this position. You will
need it to be open while you do the next few steps.
28
Check the alignment of the windshield. These two
bolts on either side of the windshield can be loosened
to allow for adjustment of the windshield alignment.
Use a rubber mallet to tap them and align the
windshield. Once aligned, tighten all bolts.

With the windshield held open, install the Rub Plate,
from inside the vehicle, by sliding the hooked piece
under the center retainer and then fastening to the
piece shown in the next step.
29
This piece of the Rub Plate has two orientations. If the
bracket isn’t tight enough, flip this piece 180°and
tighten.
30
11
*You do not need to remove the clip to do this step*
Push the head on the larger diameter end of the Gas
Spring over the ball stud on the Ball Stud Clamp until
it snaps in place.
With the windshield still open, remove the T Handle
with a 6mm allen wrench, and set it aside. Now
remove the center M6x45 button head bolt from the
brace mounting block with a 4mm allen wrench. Put
the brace mounting block cover over the brace
mounting block and replace the middle brace
mounting block bolt (M6x45mm button head) through
the hole in the cover and fasten into the captive nut on
the back side. Replace the T Handle and the M8x30
socket head bolt and tighten.
31 32

Repeat this process for the smaller diameter end of
the Gas Spring. Install this end’s clip over the ball
stud near the End Mounting Block on the Tube
Assembly. Repeat gas spring install for other side of
vehicle.
To Close: With the windshield open, pull the T Handle
swiftly and in a straight line towards you to engage
the strikers in the strike plates and close the
windshield.
To Open: With the windshield closed, twist the T
Handle clockwise
Troubleshooting:
Windshield not closing?
•The windshield requires a quick pull to latch, but you should not have to slam the windshield. If it is not closing
remove the T Handle and Brace Mounting Block Cover. Then repeat step 27 to readjust the cables/striker
position.
•Check the clearance of the gasket when closing the windshield. Find any areas where the gasket is getting
resistance when trying to close the windshield. If the resistance is on the sides, realign the windshield using step
24 & 25. If the resistance is on the bottom of the windshield remove the gas springs by opening the windshield
and then removing the gas springs by prying up the retaining ring as in step 10. Remove the hinge bolt (step
24), remove the Jam Nut from step 19, and then make sure the rod ends are fully threaded into the Hinge Half,
Upper (steps 20). Removing this Jam Nut will allow the Rod End to thread further into the Hinge Half, Upper and
therefore raise the windshield. Reassemble the windshield in the original order.
12
33 34

13
Troubleshooting:
Windshield closing without fully compressing gasket?
•The Shims from step 9 can be removed if the windshield is closing without compressing the Gasket enough.
Removing these shims will make the Gasket compress more when the strikers latch on the Strike Plates
Windshield wobbling when closing?
•This is caused by uneven Ball Stud Clamp heights or an uneven pulling motion, Re-check the Ball Stud Clamp
heights from the strike plate bolt as in step 18. Pull the windshield with a swift motion aligned with the middle of
the vehicle.
Windshield racking?
•If your windshield is crooked, this is a result of the Rod Ends being out of alignment. You will need to remove the
bolt(s) that connect the Hing Half, Lower and the Hing Half, Upper. For example, if the top driver’s side is low, the
Rod End needs to be screwed in further, retighten the Jam Nut so the Rod End stays put. Reinsert the M8x50
button head bolt that connects the Hinge Half, Lower and the Hing Half, Upper.See Step 23/24 for reference.
: Windshield
: Vehicle
: Rod End