Installation Instructions: Alpha Doors CFMOTO ZForce 500 / 800 / 800EX *** SAFETY FIRST: ALWAYS DISCONNECT THE NEGATIVE BATTERY LEAD ON YOUR MACHINE PRIOR TO PERFORMING ANY MAINTENANCE OR INSTALLATION. THE BATTERY IS LOCATED IN THE REAR OF THE MACHINE, AT THE FRONT OF THE FENDER WELL OF THE LEFT REAR TIRE. *** Step 1: Temporarily disconnect factory door nets leaving front lower bolt attached. Step 2: Remove the factory driver seat by reaching through the seat and lifting up on the quick-release latch underneath the back of the seat. Step 3: Start by removing the three (3) factory bolts underneath the side panel (see photo below). Step 4: Remove factory nylon push rivets. This includes (see photos): Four (4) rivets on top of the side panel (see photo below - left) Six (6) rivets on the forward most part of the fender flare (see below - right) (Step 4 continued on next page)
Step 4: (continued) Four (4) rivets on the forward section of the rear fender (see photo below top left) Three (3) rivets under rear fender flare on passenger side only (see photos below top right, bottom left and bottom right) Step 5: Remove rear factory side panel bolt (see photos below).
Step 6: Remove two (2) upper and two (2) lower factory bolts holding the upper tube in place. Remove the upper tube (see photo below). Step 7: Reaching in behind the plastic, remove the upper (see photo below - left) and lower (see photo below - right) factory attachment bolts for the lower tube. Lower bolt will be used in Step 10. When installing the passenger side, it is necessary to remove the gas cap to pull back fender flare where lower bolts are located under plastic. Pull fender flare out and replace gas cap during next steps. Step 8: Remove factory bolt that attaches through the plastic to the lower tube (see photo below - left). Remove the lower tube. Step 9: Remove the factory floor pan bolt (see photo below - right). Floor pan bolt will be used in step 10.
Step 10: Slide Large Bracket (see photo below left) into place and install using original hardware (lower attachment bolt of lower tube from Step 7 and floor pan bolt from Step 9). Tighten bolts completely (see photo below - right). Step 11: Remove gas cap and return fender flare to original position. Replace gas cap. Step 12: Reinstall three (3) factory side panel bolts from Step 3 and the factory rear side panel bolt from Step 5. Step 13: Reinstall all factory nylon push rivets on the side panel, fender flare and rear fender from Step 4. Step 14: Remove two (2) factory front roll bar bolts, being sure to hold mirror so it does not fall (see photo below - left). Step 15: Remove two (2) factory rear roll bar bolts (see photo below - right). Step 16: Remove factory bracket from mirror. Install the supplied Mirror Brackets (see photo below left) using factory bolts and supplied M6 Nylock Nuts (see photo below right). Set aside.
Step 17: Install the slam latch mechanism on to the door bracket using two (2) M6 x 35mm Bolts, four (4) M6 Small Washers (one under bolt head and one above nut so washers are on each side of bolt hole), two (2) M6 Nuts and snug tight (see photos below). Step 22: Install the release handle on the slam latch mechanism using two (2) M5 Bolts and two (2) M5 Nuts (see photo to left and below).
Step 18: Place door/frame on machine and insert four (4) M6 Large Washers (2 washers placed side by side) between the center door frame mount and large bracket (see photo below left). It may be necessary to add or decrease the number of washers to adjust height on frame. See Adjustment Guide for proper spacing and troubleshooting. Step 19: Place the supplied Bumper Assembly on the center door frame mount, inserting two (2) ¼ Washers and two (2) M6 x 35mm Bolts through the bumper assembly, center door frame mount and large bracket. Place one (1) ¼ washers and one (1) M6 Nuts to the underside of each bolt (see photo below right). Tighten but do not snug. See Adjustment Guide for proper spacing and troubleshooting. Step 20: Insert two (2) Small Black Spacers between the rear roll bar and door frame bracket (see photo below - top left). Insert two (2) M10 x 65mm Bolts through the door bracket, spacers and roll bar (see photo below middle). Apply two (2) Small Black Spacers to the end of each bolt then attach two (2) M10 Nuts (see photo below - bottom). Tighten but do not snug. See Adjustment Guide for proper spacing and troubleshooting.
Step 21: Take driver side mirror with the installed replacement mirror bracket and place bracket above the front door frame bracket and against the roll bar. Insert two (2) M10 x 60mm Bolts through the mirror mount, front door mount, and roll bar (see photos below - top). Apply two (2) Small Black Spacers on the interior side of the bolts and install two (2) M10 Nuts (see photos below - bottom). Tighten but do not snug. See Adjustment Guide for proper spacing and troubleshooting. Step 22: Snug bolts and nuts on front and rear roll bar mount and center mount. See adjustment guide for proper spacing and troubleshooting. Step 23: Install striker pin by removing bottom 5/16 Flange Nut DO NOT remove top nut from pin. Insert the threaded end of the Striker Pin through the center of the mount. Reattach 5/16 Flange Nut, tighten but do not snug. Step 24: Close door and latch. The striker pin should sit directly in the center of the loading mechanism after the second click. See Adjustment Guide for proper spacing and troubleshooting. Step 25: It may be necessary to adjust the door bumper at this time. See adjustment guide for proper spacing and troubleshooting. Step 26: Reinstall seats and reconnect battery. Step 27: Reconnect door nets. The center strap of the door net will now wrap around the center door frame bracket (see photo). The remaining net will be reattached to its factory setup.
Adjustment Guide: Alpha Doors CFMOTO ZForce 500 / 800 / 800EX ***PROPER ADJUSTMENT OF YOUR DOORS IS CRITICAL TO KEEP YOU AND YOUR RIDERS AS SAFE AS POSSIBE AND GET THE LONGEST LIFE OUT OF YOUR ALPHA DOORS. THIS GUIDE WILL AID YOU DURING INSTALLATION, AS WELL AS BEFORE AND AFTER USE ADJUSTMENTS TO GET THE BEST AND PROPER FIT POSSIBLE. ASSISTANCE MAY BE REQUIRED DURING ADJUSTMENT. *** Gap Adjustment: 8mm Gap (approx. 5/16 ) The gap between the front frame and door should measure no less than 8mm (approx. 5/16 ) after installed. If gap is less than 8mm, adjustments will need to be made so that door will NOT hit frame during use (see photo left). To adjust height of gap properly, push the front roll bar bracket forward and snug bolts and nuts completely (see photo below left). Then, repeat this step with the rear roll bar bracket to flex door frame and increase gap (see photo below right). Once proper height is achieved, it may be necessary to add or remove washers between center door frame mount and large bracket in step 18 of installation instructions. Additional washers have been provided for use in adjustment. Striker Pin Adjustment: After adjustment of gap, it may be necessary to adjust the striker pin so that it latches properly. The correct placement of the striker pin should set directly in the center with the loading mechanism on the second click. See photos on next page showing proper adjustment of striker pin.
Proper adjustment of striker pin Striker pin adjusted too low Striker pin adjusted too high Bumper Adjustment: After adjustment of gap and striker pin, it may be necessary to adjust the placement of the door bumper. When properly adjusted, the door should latch on the first click with no pressure. Slight pressure will be necessary when securing door latch on the second click. If door will not preload on first click, increase washers by one and test. Add washers until door latches easily on first click. If much pressure is required to preload door on first click, reduce washer by one and test. Remove washers until door latches easily on first click. Tips: After installation of doors, ride your machine through rough terrain then check fitment again. It may be necessary to make adjustments again. Always check fitment before and after each ride to see if adjustments need to be made and to get the longest life out of your doors. Over time and use, the body of your UTV may flex and alter. This may also require adjustments to be made.
Contents (cont d): Alpha Doors CFMOTO ZForce 500 / 800 / 800EX