Tools required:
:Beer
:13mm (1/2) open end wrench.
:11mm (7/16) open end wrench.
:13mm (1/2) socket.
:11mm (7/16) socket.
:A ratchet.
: 4mm (5/32) Allen key.
:T25 torx bit. (Can be found in Rzr tool kit)
:1/4in drill bit.
:drill.
Step 1: Passenger side upper panel.
Parts: small panel (both are exact same) and one rectangular bracket. 2 Allen bolts, 2 silver washers and 2 silver lock nuts.
Tools:
-4mm (5/32) Allen key.
-11mm (7/16) socket.
-13mm (1/2) socket.
-13mm (1/2) open end wrench
-ratchet
Remove upper m8 x 1.25 x 55 screw, using one 13mm wrench to hold the lock-nut. Use the 13mm socket to loosen and remove the bolt.
Line up top hole in panel, with the hole in upper weld bolster. Reinstall bolster bolt (leave loose). Align rectangle bracket with the 2 slots, with the 2 hole in panel so that the bracket clamps into the weld bolster.
Insert Allen bolts from the outside. Put a washed on the bolt and then a locknut from the inside. Use a 4mm (5/32) Allen and a 11mm (7/16) wrench to snug bolts.
[
ATTACH]146007[/ATTACH]
Attachment 146006
Check that the panel is aligned and square the edges up with the existing body lines of your plastics. Then proceed to tighten the bolster bolt (16ftlbs). Then tighten the Allen bolts (8ftlbs).
Complete! Drink a beer.
Lower passenger door panel install:
-Parts required:
:Bracket #1.
:Bracket #2.
:2x double nut welded bracket.
:4x 1/4 x 20 x 1.00 cap screws.
:4 washers.
:4 lock washers.
Tools required:
:4mm (5/32) Allen key.
:11mm (7/16) socket.
:T25 torx bit.
:1/4in drill bit
:drill
(Part A)
Remove the 6 door skin screws using the T25 torx bit.
Set the door skin to the side and attach bracket #1. It is the larger of the 2 brackets and will attach in the holes near the bottom below the door latch. Using a 1/4 -20 bolt, add a lock washer then a washer. Thread bolts into the double nut bracket placed on the outside of the door frame. Leave bolts loose enough that you can move bracket side to side.
