Polaris 2877466 User manual

RZR – CAB SYSTEM
KIT PN 2877466 The Way Out
Form #99552990 Rev Date 07.29.08 1 Printed in the USA.
If you leave the key in the ignition
switch, someone could accidentally
start the engine and seriously injure
you or other bystanders.
Remove the key from the ignition
switch before you do any
maintenance.
Application: Polaris Ranger RZR
Before you begin, read these instructions and check to be
sure all parts and tools are accounted for. Please retain
these installation instructions for future reference and parts
ordering information.
Installation Time: Approximately 60
Minutes
Carton Contents:
Rear Panel + Expanding Plugs (2)
Roof + Mudguard Kit
Left Door
Right Door + Hinge Kit + Hardware Kit
Kit Components:
QTY. Part Description
1 Hinge Base Block, (Left)
1 Hinge Base Block (Right)
2 7” D-Foam Strips
1 Latch Bracket (Left)
1 Latch Bracket (Right)
2 2” Foam Pads
2 Clamp (1”)
2 Clamp (.75”)
2 Spring Pin & Tether
4 Socket Hd Screw
4 Nylock Nut
4 2” Truss Hd Torx Screw (For pin latch
adjustment only)
4 .75” Truss Hd Torx Screw
4 Flat Washer
2 Lock & Ride expanding anchor kit
(Included in Rear Panel Kit)

RZR – CAB SYSTEM
KIT PN 2877466 The Way Out
Form #99552990 Rev Date 07.29.08 2 Printed in the USA.
Installation Supplies:
5/16” Allen Wrench
#2 Phillips Screwdriver
#27 Torx Driver
7/16” Wrench
IMPORTANT: Your Polaris accessory kit is exclusively designed for your Polaris vehicle. Please read
the installation instructions and operator’s manual thoroughly before beginning. Installation of any item is easier if the
vehicle is clean and free of debris.
INSTALLATION INSTRUCTIONS
NOTE: Remove windshield if previously installed.
Refer to windshield instructions after the cab has been
installed for re-application.
Quick tip for the installer:
•All fasteners are loosely installed from the
factory. It is the install technician’s
responsibility to tighten all fasteners during the
final adjustment process.
Install Mud Guard: Refer to mudguard instructions for
proper placement.
Rear Panel:
1. Remove all safety netting from the machine.
2. Remove both seats from machine.
3. Locate the two Lock & Ride Anchors and pre-
assemble as detailed in their respective instruction
sheet.
4. Refer to (Figure 01). Install the two Lock & Ride
anchors onto the rear panel.
5. Carefully align the rear panel over the frame and
place the upper hooks onto the top bar. Make sure
the rear panel is sitting securely on the frame.
6. Slide the Lock & Ride anchors into the respective
holes in the cargo box. Then lock the expanding
anchor plugs to secure the rear panel in place.
7. Locate a 10” D-Foam Strip. Clean the steel cab
frame below the shoulder support. Remove the self
adhesive tape, and install the D-Foam as indicated
in (Figure 02)
8. DO NOT TIGHTEN UPPER HOOK FASTENERS
AT THIS TIME.
9. Re-install vehicle seats at this time.
Roof:
1. Carefully align the roof over the top frame and
place the front hooks onto the forward most tube
frame.
2. Ensure the roof is resting evenly on the forward
frame, with the lock and ride clamps open feed the
latch between the rear panel and the upper most
rear frame tube. Once in place, snap the lock and

Fig. 01
Fig. 02
Fig. 03

RZR – CAB SYSTEM
KIT PN 2877466 The Way Out
Form #99552990 Rev Date 07.29.08 3 Printed in the USA.
ride clamps around the rear bar. (Figure 03).
3. DO NOT TIGHTEN FORWARD HOOK
FASTENERS AT THIS TIME.
Adjust Roof-Rear Panel Fitment:
1. Adjust Rear Panel: With the rear panel secured
firmly to the cargo box, position the upper hooks into
place. Ensure that they are level and tight against the
vehicle frame. Tighten rear panel fasteners at this
time.
2. Adjust Roof: With the roof loosely installed, slide
the roof forward so that it makes even contact with
the rear panel. Adjust forward hooks to make even
contact with vehicle frame. Tighten roof fasteners at
this time.
Install Drivers Side - Hinge Base Brackets:
1. Refer to (Figure 04). Ensure vehicle surface is clean
and free of oils prior to applying self adhesive foam.
Remove adhesive tape, and secure foam pad to the
vehicle hood. Please use the Hinge Base Block as
reference for proper seal location. (Figure 04).
2. Remove the (2) socket head screws and (2) nuts in
the front left frame, thread the new longer socket
head screws through the hinge base bracket, and
fasten them to the frame with included nylock nuts as
shown in (Figure 05). Torque fasteners to 25ft/lbs.
3. Repeat steps 1&2 for passenger side
Install Drivers Side - Latch Plate:
1. Locate left latch plate, and position on frame as
shown in (Figure 06). Ensure that the steel bend
contacts both the horizontal and vertical supports in
the shoulder harness.
2. Fasten the bracket to the shoulder harness using (2)
truss head torx screws, (2) flat washers, (1) 1” mount
strap, and (1) ¾” mount strap. The 1” mount strap is
for the bottom location, the ¾” mount strap is for the
upper location. Refer to (Figure 06).
3. Tighten screws at this time.
4. Repeat steps 1&2 for passenger side.
Install Door:
1. Remove door windows to help ease install. Locate
the tether/spring pin from hardware kit. Remove
upper door frame fastener and install tether as shown
in figure #7. Tether should be located on outside of
vehicle door. DO NOT TIGHTEN FASTENER AT
THIS TIME.
2. Install door to hinge base bracket by using spring pin.
3. Close door fully and proceed to the adjustment
procedure.
4. Repeat steps 1-3 for opposite side.
Fig. 04
Fig. 05
Fig. 06

RZR – CAB SYSTEM
KIT PN 2877466 The Way Out
Form #99552990 Rev Date 07.29.08 4 Printed in the USA.
Adjust Door:
1. With the door frame fasteners loose, adjust the door
vertically and horizontally to center inside the vehicle
door sill. (Refer to figure 08.)
5. Tighten all door frame hardware once proper fitment
is achieved. NOTE: When adjusting please
compensate for the weight of the door prior to
tightening fasteners.
6. Close the door to test the latch, adjust the paddle
latch, by loosening the four mounting screws and
sliding the latch either to the front or rear so that it
works properly with the latch bracket. Tighten all
screws once proper fitment is achieved. (Figure 06)
7. (Refer to figure 09)With door adjusted and latching
properly, please verify secondary pin latch. Doors
come standard with one spacer behind the pin latch.
If you feel that the door is too hard to lock, feel free
to add a 3/8” spacer, supplied with this kit. When
adding spacers, please use the auxiliary 2” Torx
screws that have been supplied in the kit. If step #7
does not give desired results for sealing, please move
forward to step #8.
8. NOTE: The RZR shoulder harness frame has a
significant amount of tolerance from the factory. If
at any time the door does not seal properly, the
shoulder harness must be bent/adjusted toward the
inside of the cab. This can be accomplished by
placing a solid bar/object between the vehicle roll
frame and the shoulder harness. Please bend
incrementally towards the inside of the vehicle until
proper results are achieved.
NOTE: Periodically check all door fasteners
and latch mounting hardware, adjust as
necessary. Note: there will be some minor
adjustment needed after initial install and use of
the cab.
Quick tip for the installer:
•Install windshield after the cab is completely
adjusted and in place. On L&R poly windshield,
do not install the center snap clamp onto the
windshield. Snap the clamp directly onto the
center frame, then orient the clamp so it can easily
receive the windshield. With the other clamps
installed onto the windshield, slide the part up the
cab frame and lock into center clamp. Now, snap
the remaining clamps onto the vehicle frame.
WARNING: Before towing your Polaris RZR, please open rear sliding window on the Lock
& Ride rear panel. Only trailer with the vehicle facing forward when cab is installed, making sure
both doors are securely closed.
Fig. 08
Fig. 09
Fig. 07