This video goes over the Rear Skeleton Doors (part number 2884399).
Required Tools and Supplies
- T15 TORX® Socket
- T30 TORX® Socket
- 10mm Socket
- 13mm Socket
- 10mm Wrench
- Ratchet
- Torque Wrench
- Multifunction Pliers
- Pry Tool
- 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 the Rear Skeleton Doors on your Polaris XPEDITION XP 5 or 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. Remove six push-pin rivets from the lower B-pillar trim with a multifunction pliers.
3. Turn the top of the trim away from the vehicle and lift the trim to disengage the lower tab.
4. Find the bracket and the limit strap on the B-pillar.
5. Remove two screws and the limit strap bracket from the rear of the B-pillar with a 10mm socket.
6. Close the door and engage the door with the striker. This will help support the door while the hinge screws are removed.
7. Remove the four hinge screws with a 13mm socket. Caution: The doors are large and may weigh up to 60 lbs/27 kg. Use assistance when lifting and moving doors if necessary.
8. Pull the door handle to disengage the striker and lift the door away from the vehicle.
9. Set the door on a flat surface with the outside facing down. Caution: Protect painted/plastic surfaces with protective cloth/tape during removal or installation.
10. Remove and retain four screws from the door and two door hinges with a 13mm socket.
11. To prepare the skeleton door, install the hinges and four screws with a 13mm socket. Torque screws to 26 ft-lbs (35 Nm).
12. Install two screws, two nuts and the limit strap bracket with a 10mm wrench and 10mm socket. Torque screws to 106 in-lbs (12 Nm).
13. Place the rear door in the opening and engage the striker with the door latch to help support the weight of the door.
14. Loosely install the four hinge screws. Do not torque at this time.
15. To adjust the rear door, start by inspecting the outer edges of the door to make sure the gaps are even on the rear side and the bottom of the door.
16. Make sure that the trim panel on the door lines up with the vehicle trim. After the door is properly positioned, torque the hinge screws to 26 ft-lbs (35 Nm).
17. After the door is properly positioned, check the engagement with the striker. Adjust the striker up or down as needed for proper latching. If the door does not seal or rattles when latched, adjust the striker inward. If the door is difficult to open, adjust the striker outward. Remove the striker cover to access the striker screws.
18. When finished adjusting the striker with a 10mm socket. Torque the striker screws to 26 ft-lbs (35 Nm) and replace the cover.
19. Thread the bracket through the limit strap and install the bracket and two screws to the B-pillar. Torque bracket screws to 106 in-lbs (12 Nm).
20. Put the lower tab of the B-pillar into the opening, turn the top of the trim toward the vehicle and install six push-pin rivets. Repeat all steps on the other side.
21. When hinges are removed from the half doors, the hinge nut plate inside the door will be loose and could fall out of place. If hinges are to be reattached to the half doors, it will be necessary to remove the trim panels from the door. With the trim panels removed, the hinge nut plate can be located and replaced in its proper position.
22. Turn the door over and remove and retain the handle cover by prying up the cover with a pry tool.
23. Remove and retain the screw to separate the handle from the actuator with a T15 TORX®.
24. Lift the handle away from the actuator and pull backwards to remove the handle. Keep the handle for later installation.
25. Remove and retain the four push-pin rivets from the front of the door with a multifunction pliers.
26. Remove and retain the three push-pin rivets from the rear of the door with a multifunction pliers.
27. Move the filler panel toward the rear and lift to remove the panel. Keep the panel for later installation.
28. Remove and retain the four screws with a T30 TORX®.
29. Move the trim panel toward the rear and lift to remove the panel. Safely store the panel if you want to reinstall factory doors later. Repeat on other side.
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.
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