KAWASAKI TERYX (K082202)
DOORS INSTALLATION INSTRUCTIONS
Please read these instructions carefully before installation to prevent injury to yourself or damage to your vehicle.
PARTS LIST:
PART DESCRIPTION QTY
1 DOOR (LEFT) 1
2 DOOR (RIGHT) 1
3 A-PILLAR MOUNT (LEFT) 1
4 A-PILLAR MOUNT (RIGHT) 1
5 RIV-NUT INSTALLER 1
6 SPRING PLUNGER 5/8”-11 2
7 SLAM LATCH 2
PART DESCRIPTION QTY
8 JAM NUT 5/8”-11 2
9 1” RUBBER BUMPER 4
10 M6 RIVET NUT 2
11 M6 x 50mm HEX HEAD BOLT 3
12 M6 x 50mm BUTTON HEAD BOLT 2
13 M6 x 20mm FLANGED HEX BOLT 2
14 M6 x 16mm BUTTON HEAD BOLT 28
PART DESCRIPTION QTY
15 10-24 x .625” BUTTON HEAD BOLT 4
16 M6 NYLOC FLANGED HEX NUT 10
17 M6 NYLOC NEX NUT 28
18 M6 HEX NUT 1
19 6mm WIDE WASHER 2
20 6mm NARROW WASHER 61
1
2
3
4
5
6
7 8
10 13
14
15
17
18
20
19
12
11
REMOVE AND RETAIN REAR B-PILLAR BOLTS
REMOVE AND RETAIN FRONT A-PILLAR BOLTS
REMOVE
WIRE FRAME LEG GUARD
FIG. 1
NOTE: PERFORM ALL
PREPARATION STEPS
ON BOTH SIDES OF
THE VEHICLE
FIG. 2
REMOVE SEATS
FROM VEHICLE
CENTER MOUNTING
HOLE. REMOVE
PLASTIC PUSH RIVET
LOCATE CENTER MOUNTING HOLE. USING A POWER DRILL,
AND A 3/8” BIT BORE THE HOLE
OUT TO 3/8” DIAMETER
RIVET NUT INSTALLATION:
Assemble the riv-nut installer as shown in the diagrams below.
#5
FIG. 3
#11 #18 #20
Be sure to adjust #18 nut so that there is enough thread
On #11 bolt to engage the
rivet nut
#10 Thread #11 bolt into #10
rivet nut
After assembly of riv-nut installer is complete, locate
the drilled hole from Fig.2 and position the riv- nut
installer so that the rivet nut is seated in the hole.
FIG. 4
Lock bolt and riv-nut
installer stationary
Turn nut
To install the rivet nut, hold down #11 bolt and #5
riv-nut installer, while tightening down #18 nut. The
bolt should gradually back out of the rivet nut expanding
the walls of the rivet nut in the drilled hole securing it in
place.a second person may be need to assist you in
holding one of the wrenches in place as shown in FIG.4
Repeat procedure on the other side of the vehicle.
INSTALL THE RIVET NUT ONTO THE
VEHICLE
PREPARATION:
1. Loosely install the pre-assembled left A-pillar mount
bracket onto the left A-pillar mounting location of the
vehicle using the retained factory bolts. Repeat the
procedure using the pre-assembled right A-pillar mount
bracket on the right side of the vehicle.
2. Position #1 door over the left side the vehicle. Align
its B-pillar mount to B-pillar mounting location of the
vehicle’s roll cage. Loosely re-install the retained
factory mounting bolts. Align the door’s center mount
above the installed rivet nut. Loosely install (1) # 13 bolt.
The lower door bumper should rest up against the
vehicle's plastics. Adjust as necessary. See Fig. 8 Repeat
procedure with #2 door on the right side of the vehicle.
A-PILLAR MOUNT ASSEMBLY:
FIG. 5 FIG. 6
#3
Install specified hardware onto the #3 mount as shown above.
Adjust the bumper depth by tightening/loosening the nuts on
each end of the bumper. Repeat procedure for #4 mount.
#16
#9
#12
#19
Install the slam latch to #3 mount using
The specified hardware. Repeat procedure for #
4 mount
#15
#7
#20
ADJUSTING NUT
LOWER DOOR BUMPER ASSEMBLY
FIG. 7 FIG. 8
#9
#16
#11 #16
#1
ADJUSTING NUT
Assemble 2 lower bumpers using the
specified hardware shown above.
Loosely install #16 nut onto 1 assembled bumper. And loosely thread
the bumper assembly into the threaded lower bumper bracket of #1
door. Adjust the bumper depth by tightening/loosening #16 nut. Repeat
Procedure on #2 door.
INSTALLATION: FIG. 9
CENTER MOUNT
B-PILLAR MOUNT
3. Loosely install #6 spring plunger
onto the door and fasten it down
using # 8 nut. Adjust the loosely
installed front A-pillar mount
so that its latch is parallel to the
pin of the spring plunger. Tighten
down the A-pillar mount securing
it to the roll cage of the vehicle.
adjust the pin depth of the spring
plunger by tightening/loosening
the adjusting nut shown to the
right. The spring plunger pin
should protrude past the slam
latch by about a 1/4”.When adjust-
ments have been made tighten
down #8 nut. Adjust the bumper
as needed. Perform procedure
for the right side door as well.
With all mounting points located and hardware loosely installed, tighten the center mounting hardware and the rear B-pillar
hardware on both doors securing them to the vehicle.
MAINTENANCE:
Periodically check to see that all bolts and fasteners are properly installed on the doors. Re-torque where necessary. Do not
operate the vehicle if any hardware are loose or missing.
For questions or concerns about this installation please contact
Pro Armor Customer Service @ 1-888-312-7667
FIG. 10
#8 #6
ADJUSTING NUT
