Required Tools and Supplies
- T25 TORX® Socket
- T27 TORX® Socket
- T30 TORX® Socket
- T40 TORX® Socket
- 4mm Allen Socket
- 10mm Socket
- Ratchet
- Torque Wrench
- Multi-Function Pliers
- Flat-Head Screwdriver
- 21/64 in (8 mm) Drill Bit
- Drill
- Eye Protection
- Nitrile Gloves
- Shop Rags
To install the full coverage fender flare kit (part number 2890407) on your RZR Pro S, follow these steps:
1. Park the vehicle on a flat, level surface, ensure the vehicle is in PARK and remove the key. Note: RZR Pro S 4 Ultimate Model Shown.
2. Begin by removing the two screws with a T40 TORX® socket to remove the center hood from the vehicle.
3. Remove the screw with a T40 TORX® socket to remove the center emblem panel from the vehicle.
4. If equipped, remove the front tweeter speakers by removing the two screws from the A-pillar cover using a T27 TORX® socket.
5. Remove the tweeter hooks from the A-pillar cover and disconnect the tweeter from the vehicle with a pick.
6. Set the tweeter speaker aside.
7. Move the A-pillar cover up to the ROPS tube.
8. Open the lid of the dash compartment by lifting it upward and removing the two screws inside with a 4mm Allen socket.
9. Remove the dash compartment by pulling up and outward. Disconnect the USB cord and pull through the grommet.
10. Remove two screws from the dash panel with a T40 TORX® socket.
11. Remove the screw from the inner dash panel with a T40 TORX® socket. Repeat on the other side.
12. Open the glove compartment by lifting it up and remove the four screws from the interior glove compartment using a T30 TORX® socket.
13. Remove the center audio panel by pulling on the top and bottom edges of the panel to disengage the four mounting tabs.
14. Pull the dash panel out and up to remove from the vehicle.
15. Pull the speaker grille out to disengage the clips. Repeat on the other side.
16. Remove the four screws from the front of the vehicle near the grille using a T40 TORX® socket.
17. Remove four push-pin rivets using a multi-function pliers.
18. Remove the screw from the inner dash panel with a T40 TORX® socket.
19. Lift up and pull the side hood panel outward to disengage tabs and remove from the vehicle.
20. Repeat this process on the other side.
21. Remove the front fender by removing the three screws from the lower area of the fender flare using a T40 TORX® socket.
22. Remove two screws and one push-pin rivet from the outside of the fender using a T40 TORX® socket and multi-function pliers.
23. Remove two push-pin rivets from the speaker area with a flat head screwdriver.
24. Remove two screws and three push-pin rivets using a T40 TORX® socket and multi-function pliers.
25. Pull the fender out to disengage tabs and remove from the vehicle.
26. Repeat this the removal process on the other side.
27. Using a T40 TORX® socket, remove the screw from the fender at the rear of the vehicle.
28. Using a T25 TORX® socket, remove two screws from the inner rear of the fender.
29. Remove two push-pin rivets from the rear of the fender using a multi-function pliers.
30. Remove two screws from the inner side of the fender with a T40 TORX® socket.
31. Remove two screws from the rear of the fender with a T40 TORX® socket.
32. Remove the rear fender from the vehicle by pulling the rear of the fender up and out. Tilt the top of the fender outward to disengage the fender from the clips at the bottom front of the fender. Tip: Clip retainers on the front lower edge may need to be depressed to remove the fender from the vehicle.
33. Repeat this process on the other side. Ensure to remove the gas cap and push the grommet through and remove the fender flare. Note: Grommet will flex through opening.
34. Reinstall the gas cap.
35. Remove three U-clips from original fender and install onto the new fender.
36. Install the front fender flare by loosely installing the front left fender flare to the vehicle frame using three kept screws.
37. Loosely install two kept screws and push-pin rivet to the front.
38. Install two kept push-pin rivets to the side.
39. Loosely install two kept screws and three push-pin rivets at the top. Torque all fender flare screws to 31 in-lbs (3.5 Nm).
40. Install the fender flap to the front fender flare using three push-pin rivets.
41. Repeat this process on the other side.
42. Install the rear fender flare by first locating the drill points on the rear fender.
43. Use a drill to make a hole at each drill point with a 21/64 in (8mm) drill bit.
44. Install spacers to the fender flare bosses. Make note of the orientation of the notch in the spacers. Important: Matching spacers and bosses are labeled A, B, C, D. Note: Reference written instructions for more detail.
45. Using a 10mm socket, loosely install the fender flare to the stock fender using screws. First, hand tighten all screws, then torque to 26 in-lbs (2.9 Nm). Important: Start with center two screws, then move to the outer two.
46. Install the fender assembly to the vehicle frame using two kept screws.
47. Install kept screw to the rear area of the fender.
48. Install the upper fender to the vehicle using two kept screws.
49. Install two kept push-pin rivets to the rear area of the fender.
50. Install two screws to the inner rear of the fender.
51. Torque all screws to 31 in-lbs (3.5 Nm).
52. Repeat this process on the other side. Ensure to reinstall the gas gasket to the fender.
53. Install the side panel by engaging the tabs on the underside and push downward.
54. Loosely install the screw to the side panel.
55. Loosely install two push-pin rivets to the side panel.
56. Loosely install two screws to the side panel.
57. Torque all screws to 31 in-lbs (3.5 Nm).
58. Repeat this process on the other side.
59. Install the speaker grille on the vehicle frame by engaging the clips on the inside of the speaker grille. Repeat on the other side.
60. Install the dash to the vehicle frame by pushing forward and down to engage the tabs on the underside of the panel.
61. Align the mounting tabs at the top and bottom of the center audio panel. Push the panel into place.
62. Loosely install four kept screws to the inside of the glove compartment. Torque to 31 in-lbs (3.5 Nm). Close the glove compartment.
63. Loosely install kept screw into the inner dash panel. Repeat on the other side.
64. Loosely install two kept screws into the dash panel.
65. Torque all screws to 31 in-lbs (3.5 Nm).
66. Put the USB cord through the grommet and install the dash compartment by pushing down and forward.
67. Install two screws to the center dash compartment. Close the lid of the dash compartment.
68. If equipped with tweeter speakers, connect the tweeter to the vehicle audio harness through the dash hole.
69. Continue by moving the A-pillar cover down the ROPS tube.
70. Install the tweeter hooks into the A-pillar cover holes.
71. Install the A-pillar cover to the vehicle with two screws.
72. Install the center hood emblem with a screw and torque to 31 in-lbs (3.5 Nm).
73. Install two screws to the center hood panel. Torque to 31 in-lbs (3.5 Nm).
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
More 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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