This video goes over the installation of the Canvas Upper Door (part number 2884398).
Required Tools and Supplies
- T15 TORX® Socket
- T30 TORX® Socket
- T40 TORX® Socket
- 10mm Socket
- 13mm Socket
- Ratchet
- Torque Wrench
- Drill
- 1/8-Inch (3mm) Drill Bit
- Trim Tool
- Pry Tool
- Flat Head Screwdriver
- Multifunction Pliers
- Eye Protection
- Nitrile Gloves
- Shop Rags
For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when installing accessories on your Polaris XPEDITION.
To install canvas upper doors on your Polaris XPEDITION XP/XP 5 or ADV/ADV 5, follow these steps:
1. Park the vehicle on a flat, level surface, ensure the vehicle is in PARK and remove the key.
2. Release the two quarter-turn latches on the grill.
3. Pivot the grill forward and lift out to remove from the vehicle.
4. Release the two rubber straps securing the hood.
5. Pivot the hood up and slide forward to remove from the vehicle.
6. Locate the sail panel on the vehicle. Remove and retain the push-pin rivet from the rear of the panel with a multifunction pliers. Note: If the vehicle is equipped with a full or half door, the door must be fully opened to remove or install the outer sail panel.
7. Remove and retain the two screws from the inner panel with a T30 TORX® and pull the panel outward and pull toward the front of the vehicle to remove.
8. Pull the A-pillar trim piece away from the vehicle.
9. To remove the front fender, remove and retain the four push-pin rivets with a flathead screwdriver.
10. Remove and retain the two screws with a T30 TORX® and T40 TORX®.
11. Pull the fender outward to disengage the upper tabs.
12. Turn the fender and lift to disengage the lower tab. Remove and set aside.
13. Find the bracket and limit strap on the A-pillar and remove two screws and the limit strap bracket with a 10mm socket.
14. Close the door and engage the door with a striker. This will help support the door while the hinge screws are removed. Caution: Doors are large and may weigh up to 60 lbs/27 kg. Use assistance when lifting and moving doors.
15. Remove the four hinge screws with a 13mm socket. The door is now being held by only the latch and the striker.
16. Pull the door handle to disengage the striker and lift the door away from the vehicle.
17. To remove the front door trim panel, set the door on a flat surface with the outside facing up. Caution: Protect painted plastic surfaces with protective cloth tape during the removal or installation.
18. Remove and retain the handle cover by prying up the cover with a pry tool.
19. Then, remove and retain the screw with a T15 TORX® to separate the handle from the actuator.
20. Lift the handle away from the actuator and pull backwards to remove the handle. Keep the handle for later installation.
21. Remove and retain the four push-pin rivets from the front of the door with a multifunction pliers or flathead screwdriver.
22. Remove and retain the four push-pin rivets from the rear of the door with a multifunction pliers or flathead screwdriver.
23. Move the filler panel toward the rear and lift to remove the panel. Keep the panel for later installation.
24. Remove and retain the four screws with a T30 TORX®.
25. Now, move the trim panel toward the rear and lift to remove the panel. Keep the panel for later installation.
26. To assemble the front door clamps, locate the 10 bosses inside the door where the holes will be drilled and drill through the center of each hole. Drill through the inside surface of the door with a 1/8-inch (3 mm) drill bit. Note: Do not damage cables or other components when drilling. It may be necessary to move cables prior to drilling.
27. Turn the door over and mount the clamps to the inside surface of the door. Install the clamps with the weld nut facing the outside of the door with a T30 TORX®. Torque screws to 62 in-lbs (7 Nm).
28. To assemble the front door trim panel, lay the door flat the with outside facing up.
29. Lower the previously removed trim panel and slide forward into the proper position.
30. Install the four retained screws, and torque to 18 in-lbs (2 Nm).
31. Install four retained push-pin rivets.
32. Then, lower the previously removed filler panel and slide forward into the proper position.
33. Install four retained push-pin rivets.
34. Install the previously removed door handle through the opening in the panel.
35. The handle must engage the hinge under the panel for the handle to work properly. The handle will audibly click into place on the loop.
36. Lower the handle over the actuator and install the retained screw to attach the handle to the actuator.
37. Push the previously removed cover into place over the actuator.
38. Install the front door by placing the door in the opening and engage the striker with the door latch to help support the weight of the door.
39. Loosely install the four door hinge screws. Do not torque at this time.
40. To adjust the front door, inspect the outer edges of the door and make sure the gaps are even on the rear side and the bottom of the door.
41. Make sure that the trim panel on the door lines up with the B-pillar trim panel. When the door is properly positioned, torque hinge screws to 26 ft-lbs (35 Nm).
42. Check engagement with the striker and adjust the striker up or down as needed for proper latching. (If door does not seal or rattles when latched, adjust striker inward. If door is difficult to open, adjust striker outward.) Remove the striker cover to access the striker screws.
43. When finished adjusting the striker, torque striker screws to 26 ft-lbs (35 Nm) and replace the cover.
44. Thread the bracket through the limit strap and install with two screws to the A-pillar. Torque bracket screws to 106 in-lbs (12 Nm).
45. To install the front canvas frame, put it on the top of the door. The tabs from the frame will be on the inside of the clamps.
46. Install the knobs to attach the frame to the clamps. Do not tighten the knobs at this time.
47. Adjust the position of the canvas frame to be centered in the door opening and tighten knobs when the frame is in the proper position.
48. Check the alignment of the door again and adjust as needed.
49. When installation is complete, there will be excess seal material hanging at the outside edge of the door. Trim seal as desired.
50. To reinstall the front fender, put the tab into the opening and turn the top of the trim toward the vehicle.
51. Push the fender inward to engage the upper tabs.
52. Install two retained screws, and torque the front (M6) to 40 in-lbs (4.5 Nm) and the rear (#14) to 30 in-lbs (3.4 Nm).
53. Install four push-pin rivets.
54. To reinstall the sail panel, put the front edge of the sail panel in place and push the panel inward and turn toward the rear.
55. Reinstall the push-pin rivet into the rear of the trim.
56. Reinstall two retained screws, and torque to 22 in-lbs (2.5 Nm).
57. Repeat all steps for the other side upper canvas door.
58. To reinstall the hood, put the tabs on the hood through the opening in the under-hood liner.
59. Lower the hood into position and pull the rubber straps down over the hooks.
60. To reinstall the grill, put the tabs on the grill through the openings in the front fascia and push the top of the grill into the correct position.
61. Push each stud in and turn one-quarter turn clockwise to secure the grill.
View the instructions for this kit by searching the Polaris Accessory Installation Instruction Site.
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.
TORX® is a registered trademark of Acument Intellectual Properties, LLC
YouTube® is a registered trademark of Google LLC
Unless noted, trademarks are the property of Polaris Industries Inc.
© 2024 Polaris Industries Inc.
