HiBoy Maverick/Commander Doors Part # HiBoy4 Maverick/Commander Doors Black

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1 Racing 3191 N Washington St. Suite 2 Chandler, AZ (800) HiBoy Maverick/Commander Doors Part # HiBoy4 Maverick/Commander Doors Black Congratulations on your purchase of the HiBoy4 doors for the Can-Am Maverick & Commander Max! These doors have been specifically engineered for the 4 seat Maverick & Commander models. Everything from the mounting points, support braces, skin angles & latch setup complements the Can-Am, so it looks like these HiBoy4 doors came straight from the factory. Be sure to check out the full line of Accessories for your Can Am vehicle at your local authorized dealer or online at Note: Doors are sold in kits (qty 1 will provide you with driver & passenger side doors). Doors come in an all black powder coat finish. Factory matching door graphics are available separately. Due to tolerances in factory Can-Am vehicles, fitment and gaps will vary from each vehicle. *Component diagram shown on page 5 for reference with associated identification numbers* Read and understand these instructions before installing product This product does not provide roll over protection Ensure doors are securely latched and locked prior to operating vehicle Do not use product if there are any signs of damage Disclaimer Off road activities can be hazardous and could lead to injury, dismemberment, paralysis and death. No warranty of representation is made as to the products ability to protect the user from any injury or death. The user assumes that risk. The acceptance and /or use of this merchandise purchased from by the customer hereby shall release from any and all liability pertaining to the use of such merchandise. Step 1: Place vehicle on a flat and level surface. Place gear selector in Park and remove keys from the ignition. Step 2: Locate 4 retaining rivets on bottom of Passenger side rocker panel. Using drill and 3/16 drill bit, drill out rivet heads. If rivets spin use adjustable pliers to hold edges of rivet while drilling. (Figure A) Step 3: Using a Flat Head screw driver and Torx bits, remove remaining fasteners from the rocker panel and set aside to be reused. Remove rocker panel and set aside. (Figure B) *Step 4: Open glove box and tug on upper fascia to remove. (Figure C) Once Fascia is removed, locate 2 upper retaining bolts for the glove box and remove. Pull on glove box to remove from vehicle. Set aside to be reinstalled. Tools Required T30 Torx T25 Torx T20 Torx (2) - 13mm Wrenches (2) - 9/16 Wrenches (2) - 5/8 Wrenches Ratchet with 6 Extension 7mm Socket 10mm Socket 7/32 Allen 3/16 Allen 4mm Allen #3 Phillips Screw Driver Flat Head Screw Driver Drill w/ 3/16, 1/4, 3/8 & 9/32 bits 1 Spade bit (Paddle bit for wood) Adjustable Pliers Utility knife

2 Step 5: Look on the inside of the front quarter panel to locate the two retaining screws and push pin for front fender/quarter panel. (Figure D) Remove and set aside to be reused. Locate retaining hardware on wheel well side of quarter panel. Remove hardware and quarter panel, setting aside to be reused. Remove window net latch and discard latch and nut. Step 6: On the outside of the vehicle, locate 2 factory holes in square down tube. Using the top hole as a guide, drill a 3/16 hole through inner plastic. (Figure E) Note: If you do not have any holes (usually on older Commander models) please refer to (Figure W) at the end of these instructions on creating these holes. Step 7: Using the 3/16 holes drilled in the last step as a guide, drill a 1 diameter hole through the plastic from inside the vehicle to allow the supplied 5/16 washers to pass through. (Figure F) Step 8: Increase the hole size in the square tube by drilling the existing holes with a 3/8 drill bit. Step 9: Locate passenger side front door striker mount (1) and striker mount hardware. (Figure G) Thread jam nut all the way on to striker pin and place a flat washer on to striker pin. Place striker pin onto mount and then secure the pin with flat washer and jam nut. Make jam nut finger tight for adjustment later on in the installation. Step 10: Place the passenger side front door strike mount (1) on the square tube and align the slots with the holes in the tube. (Figure H) Align mount slots with holes in square tube and mark the inner plastic flange where the mount interferes. Step 11: Remove mount from vehicle and trim plastic where marked to make room for the striker mount. (Figure I) Step 12: With plastic trimmed, place the striker mount back on the vehicle and insert 5/16 x2 bolts with washers through the mount and holes in the square tube. Place an additional flat washer on the end of the bolt with nylon lock nut finger tight. (Figure J) Step 13: Prior to tightening hardware, place quarter panel plastic on car to confirm alignment of bracket in plastic cut out. (Figure K) Once alignment is achieved, tighten hardware to 19 ft-lbs. Step 14: Reinstall quarter panel plastic and *glove box with factory hardware. Step 15: Reinstall factory rocker panel using retained factory hardware. In place of rivets, use supplied self-tapping ¼ x 1 Torx head bolts with flat washer. Step 16: Remove passenger seats, factory window netting and side restraint bar. Retain hardware for side restraint bar. To remove rear seat there are 4 bolts to be removed, 2 in the cab under the seat, one on the back just above the rear wheel well and one on the back below the deck. (Figure L)

3 Step 17: Remove screws retaining B pillar plastics (the piece between the front and rear door openings). Locate push-on clips on the inside of plastics near the top. (Figure M) These are removed by gently prying top of plastic away from the vehicle. Retain clips if possible to be reused. (Extra clips are provided in hardware pack) Remove fuel cap to take plastic completely off of vehicle. Return gas cap to prevent debris in tank and release of fumes. Step 18: Mount front door lower hinge bracket (3) with factory hardware from the side restraint bar, leaving loose for adjustment. (Figure N) Step 19: Locate rear door hinge mount (4), serrated flange bolt and serrated flange nut. Place upper mount for the rear door hinge (4) on inside of rear door net buckle bracket. Pivot the front door hinge (3) to align the top mount with the other upper mounts. Insert serrated bolt through all mounts from the inside. (Figure O) Install serrated nut on outside of mount until finger tight. Leave fasteners loose for adjustment later. Step 20: Locate lower mount for rear door hinge (5) and appropriate hardware. Remove the bolt retaining the factory seat belt retractor. Attach lower mount to rear door hinge (5) with button head hardware. (Figure P) Install the lower mount (5) to the inside of the stock seat belt mount using supplied hex bolt, nut and washer; leaving loose for adjustment later. (Figure Q) Step 21: Locate rear door striker mount brackets (7 & 8) and appropriate hardware. Remove the bolt retaining the factory seat belt retractor. Place outer strike mount bracket (8) between the factory seat belt retractor and the mounting tab. Place the inner strike mount bracket (7) on the opposite side of the mounting tab and fasten with supplied hex bolt, washer and nut. (Figure R) Leave loose for adjustment later. Align the inner and outer strike mount brackets and install two button head screws, nuts and washers to pinch them together. (Figure S) Install rear striker pin and leave loose for adjustment. (Figure T)

4 Step 22: Reinstall plastic on B pillar using factory hardware, making sure the hinge mounts are to the outside of the plastic. To install plastic press-on clips, use a socket to hold the outside of the clip and press over the plastic studs. Step 23: Below the front seat mount on the inside of the rocker panel, mark 3/4 up from bottom of plastic lip and drill 1/4 hole through plastics only. Slide supplied U style nut on the underside of the plastic and align with drilled hole. (Figure U) Attach door limit strap on the end grommet using a supplied 1/4 x 3/4 torx head bolt with elastic side towards the plastic. (For driver side limit strap, fold strap over so bolt goes through both grommets.) Step 24: Place brass washers onto both front and rear hinge pins. Apply anti-seize on all hinge pins and spread to make an even coat around the entire pin. (Figure V) Place front door (2) on hinges and attach limit strap to hook on door. Thread screw into top hinge until it just touches the hinge. Swing door open to verify that door opens freely. Step 24: Place brass washers onto both front and rear hinge pins. Apply anti-seize on all hinge pins and spread to make an even coat around the entire pin. (Figure U) Place front door (2) on hinges and attach limit strap to hook on door. Thread screw into top hinge until it just touches the hinge. Swing door open to verify that door opens freely. Step 25: Unlock latch and depress lever to open the latch. Carefully shut door, aligning the loose striker pin with the door latch and making sure the door does not collide with outside plastics. Due to the variances in the factory door opening, the hinge mount and/or striker mount may need to be adjusted to allow the latch to properly catch. Note: Bottom of door frame should press against plastic below seat and put tension on the door. If the bottom of the door does not touch the plastic, the door will rattle in rough terrain. Go back to step 16 and switch the mount to the inboard side of the factory tab. Step 26: With door closed and latched, lift the door until the lines on the door skin match the body lines on the factory plastics. While holding door in position, tighten the striker mount. With front door aligned, press rear door hinge mount flat against plastic and tighten hardware on front door hinge mount. Step 27: Open door and close carefully again to confirm alignment. Re-adjust accordingly. Step 28: Place rear door (6) onto hinges and thread screw into top hinge until it just touches the hinge. Swing door open to verify that door opens freely. Step 29: Unlock latch and depress lever to open the latch. Carefully shut door, aligning the loose striker pin with the door latch and making sure the door does not collide with outside plastics. Due to the variances in the factory door opening, the hinge mount and/or striker mount may need to be adjusted to allow the latch to properly catch. Step 30: With door closed and latched, verify door and striker mount locations. Tighten striker mount and all other door mount hardware. Step 31: Open door and close carefully again to confirm alignment. Re-adjust accordingly. Step 32: For the Driver side, repeat steps 2 through 29, omitting directions marked with *. Step 23: This completes the installation process. Time to ride and enjoy! ProTip: Periodically check all hardware and re-tighten if needed. For further assistance please contact us at customerservice@dragonfireracing.com or

5 Hardware List QTY SIZE LENGTH TYPE STEP USED 10 1/4" 3/4" Torx Head Self-tapping Screw 15 & /4" 1-1/4 Philips Head Button Screw 24 & /4" - USS Flat Washer /4" - U-style Clip-on Nut /16 2-1/4 Hex Head Bolt /16 1 SS Button Head Screw /16 - USS Flat Washer 10 & /16 - Nylon Lock Nut 10 & /8 2-1/2 Striker Pin 9 2 3/8 1-1/2 Striker Pin /8 1 Button Head Screw /8 - USS Flat Washer 20 & /8 - Nylon Lock Nut /8 - Jam Nut 9 & /16 1-1/2 Hex Head Bolt 20 & /16 - USS Flat Washer 20 & /16 - Nylon Lock Nut 20 & mm 20mm Serrated Flange Hex Bolt mm - Serrated Flange Nut mm - Push Nut 22 Door Component Diagram (Passenger side shown) Scan this QR code with a smart phone or tablet to watch the step-bystep installation video. To watch on a computer go to:

6 FIGURE P - Drilling your own holes Step 1: Using a straight edge or long ruler, hold flush to the bottom edge of frame tube as shown in picture. (Note that you will have to remove your rocker plastics) Step 2: Measure up from the top of your straight edge 13 1/4 ensuring that your tape measure is perpendicular to the straight edge. Ensure your mark is in the center of the tube at the 13 1/4. Step 3: Measure from the first marked hole, 2 1/8 along the center of the tube and mark your second hole. Step 4: Align bracket with marks to ensure the holes are centered & aligned. Temporarily clamp bracket in place over marks & place quarter panel plastic on car to confirm alignment of bracket in plastic cut out. (Figure K) Once alignment is achieved, unclamp bracket and drill the holes though tube using a 3/16 drill bit. Now you can continuing on to step 7.