Ball Cage Kit

1. Push the seat assembly forward to the raised position.

2. Slide the seat assembly to the side out of the pins, and lift the seat assembly upward (Figure 2).

   

   Figure 2

   1. Pins

Remove the 3 flange bolts (5/16 x 3/4 inch) and 3 flange nuts (5/16 inch) securing the right and left handholds; remove the handholds (Figure 3 and Figure 4).

Figure 3

Left Handhold Shown

1. Left handhold
2. Flange bolt (5/16 x 3/4 inch)
3. Flange nut (5/16 inch)

Figure 4

Right Handhold Shown

1. Right handhold
2. Flange bolt (5/16 x 3/4 inch)
3. Flange nut (5/16 inch)

1. Disconnect the batteries; refer to your machine Operator’s Manual.

   Note: Correctly follow the procedure for disconnecting the batteries. Disconnect the main negative-battery cable (black), then disconnect the main positive-battery cable (red).

2. Remove the charger and the charger cable from the charger bracket (Figure 5).

   

   Figure 5

   Left Side Shown

   1. Charger
   2. Charger bracket

3. Remove the 4 torx-head screws (M6.0 x 22 mm) securing the charger bracket to the left side panel (Figure 6).

   

   Figure 6

   Left Side Shown (Top View)

   1. Left side panel
   2. Charger bracket
   3. Torx-head screw (M6.0 x 22 mm)

4. Remove the 4 torx-head screws (M6.0 x 22 mm) from the left side panel and remove it (Figure 7).

   

   Figure 7

   Left Side Shown

   1. Left side panel
   2. Torx-head screw (M6.0 x 22 mm)

5. Repeat step 5 on the right side.

1. Disconnect the vent tube and fuel line from the fuel tank (Figure 8).

   Danger

   In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property.

   • Drain fuel from the fuel tank when the engine is cold. Do this outdoors and in an open area. Wipe up any fuel that spills.

   • Never smoke when handling fuel, and stay away from an open flame or where a spark may ignite fuel fumes.

2. Remove the 2 screws securing the hold-down to the left side panel, and remove the hold-down (Figure 8).

3. Remove flange bolt securing the fuel tank to the fuel-tank tray and remove the fuel tank (Figure 8).

   

   Figure 8

   Left Side Shown (Top View)

   1. Fuel tank
   2. Screw
   3. Hold-down
   4. Fuel line
   5. Vent hose
   6. Flange bolt

4. Remove the 6 torx-head screws (M6.0 x 22 mm) from the left side panel and remove the side panel (Figure 9).

   

   Figure 9

   Left Side Shown (Top View)

   1. Side panel
   2. Torx-head screw (M6.0 x 22 mm)

5. Disconnect the negative (–) battery cable from the battery and then the positive (+) battery cable as shown in Figure 10.

   

   Figure 10

   Right Side Shown (Top View)

   1. Nut
   2. Positive (+) battery cable
   3. Bolt
   4. Negative (–) battery cable

6. Remove the 2 flange-head bolts (5/16 x 3/4 inch) that secure the battery tray to the frame and the 4 torx-head screws (M6.0 x 22 mm) that secure the right side panel, and remove the right side panel (Figure 11).

   Note: The battery comes off with the right side panel as shown in Figure 11.

   

   Figure 11

   Right Side Shown (Top View)

   1. Flange-head bolt (5/16 x 3/4 inch)
   2. Torx-head screw (M6.0 x 22 mm)
   3. Right side panel

Figure 12

Remove the 10 plastic rivets and the cable tie from each rubber cover and remove the rubber covers (Figure 13).

Figure 13

Left Side Shown

1. Plastic rivet (10)
2. Rubber cover
3. Cable tie

Figure 14

1. Align the floor brace to the machine as follows:

   • Align the flanges of the floor brace flush to the side frame channel, forward floor channel, and rear frame channel of the machine (Figure 15).

   • Align the floor brace parallel to the floor (Figure 15).

   

   Figure 15

   Marking the forward floor channel

   1. Front of the machine
   2. Forward floor channel
   3. Floor brace
   4. Side frame channel
   5. Rear floor channel

2. Clamp the floor brace to the side frame channel and floor channels.

3. Using the floor brace as a template, mark the hole locations on the side frame channel and floor channels (Figure 15, Figure 16, and Figure 17).

   

   Figure 16

   Marking the side frame channel

   1. Front of the machine
   2. Forward floor channel
   3. Floor brace
   4. Side frame channel
   5. Rear floor channel
   

   Figure 17

   Marking the rear floor channel

   1. Front of the machine
   2. Forward floor channel
   3. Floor brace
   4. Side frame channel (left)
   5. Rear floor channel
   6. Side frame channel (right)

4. Remove the floor brace from the machine.

5. Centerpunch the 10 marks that you made in step 3 of Drilling the Frame Channels.

   

   Figure 18

   1. Rear floor channel
   2. 8 mm (5/16 inch) drill bit
   3. Side frame channel
   4. Forward floor channel
   5. Front of the machine

6. Drill the side and floor channels at the centerpunch marks with a 8 mm (5/16 inch) drill bit (Figure 18).

7. Repeat steps 1 through 6 for the floor brace at the other side of the machine.

1. Align the holes in the floor brace with the holes that you drilled in the side and floor channels (Figure 19).

   

   Figure 19

   1. Floor brace
   2. Rear floor channel
   3. Front of the machine
   4. Flange locknut (5/16 inch)
   5. Flange-head bolts (5/16 x 1 inch)
   6. Forward floor channel
   7. Side frame channel

2. Assemble the floor brace to the side and floor channels with 10 flange-head bolts (5/16 x 1 inch) and 10 flange locknuts (5/16 inch) as shown in Figure 19.

3. Torque the flange-head bolts and flange locknuts to 19.8 to 25.4 N∙m (175 to 225 in-lb).

4. Repeat steps 2 through 3 for the floor brace at the other side of the machine.

1. Align a ROPS bracket with the 2 holes behind the seat base and the hole toward the front of the frame rail as shown in Figure 20.

   

   Figure 20

   Left Side Shown

   1. Hole toward the front of the frame rail
   2. 2 holes behind the seat base

2. Using a clamp, secure the ROPS bracket in place.

3. Mark the hole locations on the ROPS bracket (Figure 20).

4. Using a ROPS bracket as a guide, drill 3 holes (13.5 mm or 17/32 inch) into the frame (Figure 21).

   

   Figure 21

   Left Side Shown

5. Repeat this procedure on the other side.

1. Cut the rubber covers using the measurements shown in Figure 22.

   Note: The cuts in the rubber cover allow for space to install the ROPS brackets.

   

   Figure 22

   1. Location of cut

2. Install each rubber cover using the previously removed 10 plastic rivets and a cable tie (Figure 23).

   Note: If the previously removed rivets are damaged or missing, replace them with the rivets provided in this kit.

   

   Figure 23

   Left Side Shown

   1. Plastic rivet (10)
   2. Rubber cover
   3. Cable tie

Trim the side panels using the measurements shown in Figure 24.

Figure 24

1. Trim to this line.
2. Trim to this corner.

1. Install a ROPS bracket using 3 flange-head bolts (1/2 x 3 inches), 5 flat washers (1/2 inch), and 3 locknuts (1/2 inch) as shown in Figure 25.

   Note: Ensure that you install the 2 flat washers (1/2 inch) on the outside as shown in Figure 25.

   

   Figure 25

   Left Side Shown

   1. Flat washer (1/2 inch)
   2. Locknut (1/2 inch)
   3. Flange-head bolt (1/2 x 3 inches)
   4. ROPS bracket

2. Torque the 3 flange-head bolts (1/2 x 3 inches) to 94 to 108 N∙m (70 to 80 ft-lb).

3. Repeat this procedure on the other side.

1. Secure 1 side of the roll bar to a ROPS bracket using 2 flange-head bolts (1/2 x 3-1/2 inches) and 2 locknuts (1/2 inch) as shown in Figure 26.

   

   Figure 26

   Left Side Shown

   1. Roll bar
   2. Locknut (1/2 inch)
   3. ROPS bracket
   4. Flange-head bolt (1/2 x 3-1/2 inches)

2. Torque the 2 flange-head bolts (1/2 x 3-1/2 inches) to 94 to 108 N∙m (70 to 80 ft-lb).

3. Repeat this procedure on the other side.

For Electric Machines

1. Install the left side panel using the previously removed 4 torx-head screws (M6.0 x 22 mm) as shown in Figure 7.

2. Secure the charge bracket to the left side panel using the previously removed 4 torx-head screws (M6.0 x 22 mm) as shown in Figure 6.

3. Secure the charger and the charger cable to the charger bracket (Figure 5).

4. Repeat step 1 on the right side.

For Gasoline Machines

1. Install each side panel using the previously removed torx-head screws (M6.0 x 22 mm) as shown in Figure 9 and Figure 11.

2. Secure the fuel tank to the fuel-tank tray using the previously removed flange bolt (Figure 8).

3. Secure the hold-down to the left side panel using the previously removed 2 screws (Figure 8).

4. Connect the vent tube and fuel line to the fuel tank (Figure 8).

Install the 2 handholds using the previously removed 3 flange bolts (5/16 x 3/4 inch) and 3 flange nuts (5/16 inch) on each side (Figure 3 and Figure 4).

1. Install a seat latch using a hex-head bolt (7/16 x 1 inch), 2 flat washers (7/16 inch), and a locknut (7/16 inch) as shown in Figure 27.

   

   Figure 27

   1. Hex-head bolt (7/16 x 1 inch)
   2. Flat washer (7/16 inch)
   3. Seat latch
   4. Locknut (7/16 inch)

2. Torque the hex-head bolt (7/16 x 1 inch) to 68 to 81 N∙m (50 to 60 ft-lb).

3. Repeat steps 1 and 2 to install the other seat latch.

4. Install a seat belt using a hex-head bolt (7/16 x 1 inch), 2 flat washers (7/16 inch), and a locknut (7/16 inch) as shown in Figure 28.

   

   Figure 28

   1. Locknut (7/16 inch)
   2. Flat washer (7/16 inch)
   3. Seat belt
   4. Hex-head bolt (7/16 x 1 inch)

5. Torque the hex-head bolt (7/16 x 1 inch) to 68 to 81 N∙m (50 to 60 ft-lb).

6. Repeat steps 4 and 5 to install the other seat belt.

1. Lift up the handle of the rubber latches at each side of the hood (Figure 40).

   

   Figure 40

2. Rotate the hood forward.

3. While supporting the hood, push the pivot latch inward and move the hood rearward until the clevis pin of the hood clears the latch (Figure 41).

   

   Figure 41

   1. Pivot latch
   2. Clevis pin

4. Repeat step 3 at the other side of the hood.

5. Remove the hood from the machine.

1. While supporting the bumper, remove the 8 flange-head bolts that secure the bumper to the bumper mounts and headlight brackets (Figure 42)

   

   Figure 42

   1. Bumper
   2. Bumper and headlight mount
   3. Flange-head bolt

2. Remove the bumper from the machine.

1. Remove the 2-socket connector of the machine wire harness from the 2–pin connector at the back of the head light (Figure 43).

   Note: Retain the clips for assembly.

   

   Figure 43

   1. Headlight-adjusting nut
   2. Headlight bracket
   3. Clip
   4. 2-socket connector (machine wire harness)

2. Remove the 3 clips from the 3 headlight-adjusting nuts, and remove the headlight from the headlight bracket (Figure 43).

3. Inspect the headlight mount brackets for the headlight guard mounting holes.

   If the headlight mount brackets do not have mounting holes, use the measurements in Figure 44 to drill 2 holes—11 mm (7/16 inch) in each of the headlight mount brackets.

   

   Figure 44

   View from under the front hood

   1. Guard mounting holes (headlight mount bracket)
   2. Drill bit 11 mm (7/16 inch)
   3. 37 mm (1-7/16 inches)

4. Assemble the headlight guards onto the headlights as shown in Figure 45.

   

   Figure 45

   1. Headlight guard
   2. Headlight

5. Align the 3 headlight-adjusting nuts through the holes in the headlight mounting bracket and secure the nuts with the clips (Figure 43) that you removed in step 2 .

   

   Figure 46

   1. Headlight-adjusting nut
   2. Headlight bracket
   3. Clip
   4. 2-socket connector (machine wire harness)

6. Connect the 2-socket connector of the machine wire harness to the 2-pin connecto at the back of the headlight (Figure 46).

7. Secure the head light guard to the headlight mount brackets (Figure 45) with the 4 flange bolt (5/16 x 5/8 inch).

   

   Figure 47

   1. Headlight guard
   2. Flange bolt (5/16 x 5/8 inch)

1. Assemble the ball-picker mount onto the bumper support as shown in Figure 48.

   

   Figure 48

   1. Ball-picker mount
   2. Bumper support

2. Loosely assemble the bottom bracket onto the ball-picker mount (Figure 49) with 4 flange bolts (3/8 x 1 inch) and 4 flange locknuts (3/8 inch).

   

   Figure 49

   1. Bottom bracket
   2. Flange locknut (3/8 inch)
   3. Ball-picker mount
   4. Flange bolt (3/8 x 1 inch)

3. Align the rear-most edge of the bottom bracket with the edge of the access opening in the center-channel plate (Figure 50).

   

   Figure 50

   1. Hole (Bottom bracket)
   2. Center-channel plate

4. Mark the 4 hole locations of the bottom bracket onto the center-channel plate as shown in Figure 50.

5. Remove the 4 flange bolts (3/8 x 1 inch), 4 flange locknuts (3/8 inch), and bottom bracket from the ball-picker mount (Figure 49).

6. Centerpunch the 4 marks that you made on the center-channel plate in step 4.

7. Drill 4 holes 10 mm (3/8 inch) in the center-channel plate at the centerpunch marks that you made in step 6 as shown in Figure 51.

   

   Figure 51

   1. Drill bit 10 mm (3/8 inch)
   2. Center-channel plate

1. Loosely assemble the bottom bracket, ball-picker mount and center-channel plate as shown in Figure 52 with 8 flange bolts (3/8 x 1 inch) and 8 flange locknuts (3/8 inch).

   

   Figure 52

   1. Flange bolt (3/8 x 1 inch)
   2. Ball-picker mount
   3. Flange locknut (3/8 inch)
   4. Bottom bracket

2. Mark the 6 hole locations of the bottom bracket onto the center-channel plate as shown in figures Figure 53, Figure 54, and Figure 55.

   

   Figure 53

   1. Hole (Ball-picker mount)
   2. Front frame channel
   

   Figure 54

   1. Ball-picker mount
   2. Left side of the machine
   3. Front frame channel
   

   Figure 55

   1. Front frame channel
   2. Right side of the machine
   3. Hole (Ball-picker mount)

3. Remove the 8 flange bolts (3/8 x 1 inch), 8 flange locknuts (3/8 inch), bottom bracket, and ball-picker mount from the machine (Figure 52).

4. Centerpunch the 6 marks that you made on the center-channel plate in step 2.

5. Drill 6 holes 10 mm (3/8 inch) in the center-channel plate at the centerpunch marks that you made in step 4.

   

   Figure 56

   1. Front frame channel
   2. Drill bit 10 mm (3/8 inch)

1. Assemble the ball-picker mount and the bottom bracket to the front frame channel and center-channel plate (Figure 57, Figure 58, and Figure 59) with 14 flange bolts (3/8 x 1 inch) and 14 flange locknuts (3/8 inch).

   

   Figure 57

   1. Flange bolt (3/8 x 1 inch)
   2. Ball-picker mount
   3. Flange locknut (3/8 inch)
   4. Bottom bracket
   

   Figure 58

   1. Flange bolt (3/8 x 1 inch)
   2. Ball-picker mount
   3. Bottom bracket
   4. Flange locknut (3/8 inch)
   

   Figure 59

   1. Flange bolt (3/8 x 1 inch)
   2. Ball-picker mount
   3. Flange locknut (3/8 inch)
   4. Top of the machine

2. Torque the bolts and nuts to 37 to 45 N∙m (27 to 33 ft-lb).

1. On the back side of the bumper, mark 1 inch above the bottom of the bumper in the depressed center area as shown in Figure 60.

   

   Figure 60

   1. Area to trim
   2. 1 inch from the bottom

2. Cut out the area marked to create clearance for the ball-picker mount.

1. Support the bumper so that it aligns with the bumper and headlight mount as shown in Figure 42.

2. Install the bumper with the 8 flange-head bolts removed in Removing the Hood and Bumper.

1. With the front of the hood rotated forward, align a clevis pin at the front of the hood with the corresponding spring latch as shown in Figure 41 of Removing the Hood and Bumper.

2. Slide the clevis pin into the notch so that it is secured by the pivot latch.

3. Repeat step 2 at the other side of the hood.

4. Lower the hood and secure it with the rubber latches at each side of the hood as shown in Figure 40.