Bear Claw V.2 RZR Doors (2-Seat) Installation Instructions - Polaris RZR Forum - RZR Forums.net
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post #1 of 9 Old March 28th, 2015, 12:40 PM Thread Starter
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Bear Claw V.2 RZR Doors (2-Seat) Installation Instructions

Bear Claw V.2 RZR Doors (2-Seat)

Installation Instructions


Tools Needed
• 3/8” Drive Ratchet
• 7/16” wrench
• 1/2" wrench
• 7/16" socket
• 1/2" socket
• 9/16" socket
• 5/32" Allen wrench
• 5/16" Allen wrench
• Torx T-27 screwdriver bit
• Plastic hammer (optional)

For side bolster removal, a plastic rivet removal tool and pry bar may also be helpful, depending on your model of RZR.

Before you get started, unpack everything, lay it out, and ensure that nothing is missing.

Package Contents (see figure 1)
1. Left door ("Driver side")
2. Right door ("Passenger side")
3. Left door latch ("Driver side")
4. Right door latch ("Passenger side")
5. Hardware Kit



Hardware Kit Contents (see figure 2)
1. Center Bracket, Driver
2. Center Bracket, Passenger
3. Door Pins
4. Roll Cage mounting bolts
5. Roll Cage mounting locknuts
6. Door Pin washers
7. Center Bracket bolts
8. Center Bracket locknuts
9. Roll Cage bolt washers



Installation Instructions

1. Remove side nets (if still installed).
Unclip the nets from the Roll Cage, remove the Torx screws, and set the nets aside. I suggest re-installing any removed screws/bolts/nuts for storage after the net is removed.

2. Remove side bolsters
If your RZR has a stub post at the bottom for the side bars, removal will be simple. But if your side bars curve down into the body and disappear under some plastic, you are in for a bit of extra work, as follows:
A pry bar may be helpful to bend the plastic tabs of the floor pan and battery box out of the way in order to reach the upper bolt and locknut. Remove the plastic rivets from the rocker panel so you can pry it back to reach the lower bolt and locknut. You may be able to reach the locknut with a socket and a few long ratchet extensions connected together, inserted at the rear wheel well. Or, you may choose to remove the rocker panel entirely, or remove the skid plate to reach the lower bolt and locknut from under the vehicle.

Your RZR should now be free of side bolsters (see figure 3).



3. Remove Factory Hardware to Prepare for Door Installation
a. Remove the outer bolt and locknut from the "B" pillar (behind the seats) (see figure 4).



b. Remove the T27 Torx bolt from the center of the cab area beside the seat retention bars (see figure 5).



c. Remove the Allen bolts and locknuts from the "A" pillar (on the dashboard) (see figure 6).



4. Prepare the Doors for Installation
Open the doors about 90 degrees, and they will stand up on their own while you install the door pin and center bracket.

5. Install Center Brackets
Determine the correct orientation of the center brackets (see figure 7) and loosely attach them with the supplied Allen head bolts and locknuts. Do not fully tighten them yet.

Note: The bracket should be installed with the angled surface toward the front of the vehicle, with the bolt slots down. It is recommended to install the bolts with the locknuts facing inward, toward the vehicle (see figure 7).



6. Install the Door Pin
Put the smaller washers on the door pin bolts, put them through the door pin slots, slide the sleeves over the bolts, and attach the locknuts (see figure 8). Do not fully tighten them yet.

7. Hang the doors
a. Close the doors gently, keeping in mind that your door pin is not fully tightened.
b. Pick up the doors and carefully fit them into place on the RZR. Note that the hole in the rear door mount bracket should line up with the hole for the "B" pillar bolt and locknut you removed. The front mounting bracket goes on the outside of the roll cage stub coming up out of the dashboard (see figure 9).
c. Line up the center brackets and put the factory Torx T27 bolts back into the center area (see figure 7). Do not fully tighten them yet.

Note: The doors will now be held loosely in place while you install the remaining hardware.




(continued next post)
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-=-=-=-=-=-
Check out my UTV Guides to Washington State at http://www.utvadventuresllc.com!
-=-=-=-=-=-
Sterley, Paul

Last edited by Scoundrel; April 3rd, 2015 at 11:19 PM.
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post #2 of 9 Old March 28th, 2015, 12:41 PM Thread Starter
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Re: Bear Claw V.2 RZR Doors (2-Seat) Installation Instructions

9. Install the "B" Pillar Bolt and Locknut
Put the bolts and locknuts back on. Do not fully tighten them yet.

10. Install the "A" Pillar Bolts and Locknuts
a. Using the provided hardware, put a washer on each bolt, then slide it through the holes in the roll cage system.
b. Insert the locknuts in the groove on the other side of the roll cage system. Do not fully tighten them yet.

Note: At this point, the doors are basically installed. You could tighten the bolts and be done at this point. However, it is likely that your doors will need some minor adjustment, unless you are installing them on a brand new RZR that has not seen dirt yet - but even then, there can be factory variances. In most cases, the doors will only need minimal adjustment, if any. If your RZR has ever been in a "rubber side not down anymore" situation, or you've been high centered on obstacles with some force involved, your frame might not be completely straight, or your body panel mounting brackets might have been bent, and you may need a little more door adjustment than most installations normally require. So, on to alignment:

11. Check and Adjust Door Frame Alignment
a. Tighten the frame bolts and center bracket just enough that the frame cannot move on its own, but you can move it by tapping it with a plastic hammer.
b. Check the doors to make sure they fit correctly. Does the door frame follow the contour of the RZR body? Are there any large gaps between the frame and body?
c. If needed, make small adjustments by tapping on the door frame near the mounting points until the door frame is seated in the correct position.
• The gap between the nose triangle at the front of the frame and the latch area can be adjusted by tapping the slotted nose piece where it bolts to the roll cage (see figure 10). The slots allow for significant gap reduction.



• The door frame can be moved inward and outward by adjusting the “B” pillar area (see figure 11). Note that the bolt hole is slotted and can move about 1/2", which can make a big difference in the door angle.
• Moving the center bracket inward and outward on its slot can make a big difference in how the door frame fits against the RZR body. The bracket can also move forward and backward in additional slots to find the right fit (see figure 7).



12. Alignment By Bending
As a last resort, if the built-in slots cannot adjust the door to fit your RZR properly, you can apply some force to adjust the angles by bending the mounts (see figures 12a and 12b). Be very careful not to apply too much force. Do it in small amounts and check the results.





a. Check the door level. When it is closed and latched, is the top bar on the door lined up with the top bar on the door frame that mounts to the roll cage?
b. Check the door tilt. When it is closed and latched, is there a gap at the bottom front corner of the door?

14. Door Pin Adjustment and Final Bolt/Nut Tightening
a. Adjust the elevation of the door pin so that it easily enters the striker, and when it is closed, there is metal on metal contact to eliminate "chatter". When you shake the door, it should not rattle. When you have achieved this, tighten the locknut.
b. Tighten the main mounting bolts and locknuts, except the center bracket. Check the alignment again after each bolt and locknut is tightened.
c. Tighten the center bracket’s T27 Torx bolt, and the Allen head bolts and locknuts.

You’re done!
Enjoy your new UTV Giant doors, and check out our graphics packages, if you have not already done so!

Problems with the installation? Please call UTV Giant at 949-35-GIANT(44268) between 9 a.m. and 5 p.m. (Pacific).
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-=-=-=-=-=-
Check out my UTV Guides to Washington State at http://www.utvadventuresllc.com!
-=-=-=-=-=-
Sterley, Paul

Last edited by Scoundrel; April 3rd, 2015 at 11:18 PM.
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post #3 of 9 Old March 28th, 2015, 02:37 PM
 
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Re: Bear Claw V.2 RZR Doors (2-Seat) Installation Instructions

WOW.... FedX showed up this morning with my new doors, and then the published instructions show up. Way to go!!! Paul and thanks.... Bryan
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post #4 of 9 Old March 28th, 2015, 02:39 PM Thread Starter
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First Name: Paul Sterley
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Re: Bear Claw V.2 RZR Doors (2-Seat) Installation Instructions

Quote:
Originally Posted by bz corners View Post
WOW.... FedX showed up this morning with my new doors, and then the published instructions show up. Way to go!!! Paul and thanks.... Bryan
Awesome! Glad the timing worked out.
And you get to be my tester for the instructions!

It's a little different trying to follow someone else's instructions, totally different perspective than when writing them. Let me know how it goes!

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Check out my UTV Guides to Washington State at http://www.utvadventuresllc.com!
-=-=-=-=-=-
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post #5 of 9 Old March 28th, 2015, 09:28 PM
 
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Re: Bear Claw V.2 RZR Doors (2-Seat) Installation Instructions

Nice. Wish I had this when installed mine. Thank you!


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post #6 of 9 Old April 3rd, 2015, 10:53 PM
 
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Re: Bear Claw V.2 RZR Doors (2-Seat) Installation Instructions

Paul.... Sorry it took awhile to respond. Used your written instructions and installed the doors with NO problems. It took about 45 minutes. On your "tools required" list you might add a rubber or plastic hammer. You had mentioned that item in your adjustment section. Also, only my preference, but it would have been nice to not move back and forth between the instructions and pictures. Would have liked the pictures shown as the instructions referenced them. Besides that, great write up and easy to follow. Thanks.
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post #7 of 9 Old April 3rd, 2015, 11:07 PM Thread Starter
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Re: Bear Claw V.2 RZR Doors (2-Seat) Installation Instructions

Thank you for the feedback.

The instructions were optimized to be printed on paper and shipped with the doors (and I think they will be in the future), or downloaded as a PDF from the UTV Giant website.
In those versions, the pictures are more inline with the text (but still grouped in some cases). Then I copied/pasted into the forum, so the layout was lost.

One challenge I have is that the forum will only allow 10 photos per post. Maybe I'll go back and split it into two posts and put the images inline.

-=-=-=-=-=-
Check out my UTV Guides to Washington State at http://www.utvadventuresllc.com!
-=-=-=-=-=-
Sterley, Paul

Last edited by Scoundrel; April 3rd, 2015 at 11:20 PM.
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post #8 of 9 Old October 1st, 2017, 12:29 PM
 
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Re: Bear Claw V.2 RZR Doors (2-Seat) Installation Instructions

Just wanted to say thanks for this write-up! Got my doors installed this morning, great product and an easy job. Both my wife and pup are very pleased with the results!

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post #9 of 9 Old October 1st, 2017, 12:57 PM Thread Starter
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Re: Bear Claw V.2 RZR Doors (2-Seat) Installation Instructions

Quote:
Originally Posted by Wintyfresh View Post
Just wanted to say thanks for this write-up! Got my doors installed this morning, great product and an easy job. Both my wife and pup are very pleased with the results!

Awesome! Never expected those instructions to still be helpful this much later.

-=-=-=-=-=-
Check out my UTV Guides to Washington State at http://www.utvadventuresllc.com!
-=-=-=-=-=-
Sterley, Paul
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