Polaris General 60 Rackzilla Instructions Kit Numbers: 8002200 Wicked Bilt offers a limited warranty against all manufacturer defects of their kits and supplied parts. Wicked Bilt will not honor any warranty on any parts that have been modified or improperly installed. Full refund will NOT be granted to any kits that are damaged, scratched, or altered in any fashion. Wicked Bilt will not reimburse any labor money to the customer to change out the part even under a warranty repair. Remember before beginning installation, to insure that you are in a well lit, organized work area. Engage the parking brake, disconnect the battery until power is needed and chock or block the rear wheels to insure the vehicle is stable. pg. 1 657710
8002200: - 2017 General 1000 PS (60 ) - 2017 General 1000 4P MD - 2017 General 1000 4P PS - 2017 General 1000 EPS - 2016 General 1000 EPS # Part # Description Qty 1 8002200 Rack & Pinion Assembly 1 2 8028460 D.S. Outer End 1 3 8028470 P.S. Outer End 1 4 120500 5/16-18 Locknut 5 5 231680 5/16-18 x ¾ Hex Bolt 2 6 232110 5/16-18 x 3 ¾ Cap Screw 3 Installation: 1. Park vehicle on a flat surface. Center the steering wheel. With a tape measure, measure the distance between the 2 front wheels from the same spot on the tread. Measure the front of the tires and the rear of the tires. The difference is your total toe. Record that measurement. You may need to reset it there when the new rack is installed. NOTE the Rackzilla is preset to factory length. 2. Lift the vehicle so that the wheels are off the ground and secure with jackstands. NOTE you can remove wheels for eaiser installation but not nessasary. pg. 2 657710
3. Remove the outer tie rod end bolts from the steering arms on both sides of the vehicle. Note: You may require a mallet for this. 4. Next if a winch is installed remove the 4 bolts from the winch the two power wires and control plug. Locate the hook and remove from cable. Gently take out the winch. Note take pictures or mark the two power wires on the winch. 5. Now remove the winch mounting plate and set aside. pg. 3 657710
6. Remove the pinch bolt on the U-Joint connecting the steering shaft to the rack and pinion. 7. Remove the 5 bolts that hold the rack housing to the frame. 8. To make removal of the OEM rack easier remove the four bolts securing the front differential and slide it forward. pg. 4 657710
9. Now remove the two sway bar bolts and let it hang. 10.With all the fasteners disconnected you can now pull down on the rack to disengage the u-joint from the pinion and remove the rack from the vehicle. pg. 5 657710
10. Install the new rack assembly in place of the old, making sure that your rack is centered. This can be seen by the mark on the pinion. Spline the u-joint onto the pinion and secure the rack into position using the hardware provided. Tighten the bolts to 40 ft lbs. 11. Install the thru bolt into the U- Joint connecting the lower shaft assembly and tighten to 40 ft lbs. Note: The steering shaft and the pinion spline have a blind tooth. They must be lined up in order to go together. pg. 6 657710
12. Place the new tie rod end on the steering arm making sure to mimic the old setup coming in from the top of the spindle. Install the rod end nut, and torque it to 35 ft lbs. 13. Reinstall winch plate and winch. Make sure the two power wires are on the correct posts and the controller plug is plugged in. 14. Measure from the same spots on your front tires and set your toe to what you had previously recorded. To adjust the toe, loosen the jam nut and turn the inner tie rod in or out as needed. Tighten the jam nut and make sure the steering wheel is centered. It may be necessary to remove the steering wheel and re-center it. You are now ready to drive. 15. Congratulations! Your Rackzilla is now installed! 1555 Enterprise Parkway Twinsburg OH 44087 800-338-9080 WWW.WICKEDBILT.COM 9/3/15 Copyright 2015 by Wicked Bilt. All rights reserved. No part of these materials can be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without permission in writing from Wicked Bilt. pg. 7 657710