Polaris 2891680 Lock & Ride Clear Full Glass Windshield Instruction Manual

1. Product Overview

The Polaris 2891680 Lock & Ride Clear Full Glass Windshield is designed for the Ranger 1000 Crew models. This windshield features automotive-quality laminate safety glass, constructed with an interlayer of polyvinyl butyral (PVB) for enhanced protection and to maintain glass integrity even if broken. It is engineered with a tight-fitting, 360-degree gasket seal, ensuring a seamless fit to your vehicle's roof to protect against external elements. The design provides clear views, contributes to interior sound dampening, and offers UV and cold weather protection through its shatterproof, tempered safety glass. This durable, scratch-resistant curved glass ensures robust protection during operation.

This Full Glass Windshield is a component of the Pro Shield Cab System, offering unparalleled sealing technology tested to military standards for dust, water, and other environmental factors.

2. Safety Information

• Proposition 65 Warning: This product may contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
• Safety Rating: DOT Certified.
• Always ensure all components are securely fastened before operating the vehicle.
• Installation should ideally be performed by two individuals to ensure proper alignment and safety.

3. Package Contents

Verify that all items listed below are present in your package:

• Windshield (1)
• Installation Hardware (screws, nuts, washers, brackets, seals, hydraulic rods) - Specific quantities may vary, refer to the included parts diagram.

Figure 1: Exploded view diagram of the Polaris 2891680 windshield and its components.

4. Installation Instructions

The following steps provide a general guide for installing a full glass windshield. Specific details may vary. It is recommended to consult the detailed instructions provided with your product for precise steps.

4.1. Preparation

1. Ensure the vehicle is parked on a level surface and the engine is off.
2. Gather all necessary tools (hexagonal wrench, open-end wrench, electric drill if applicable).
3. Remove any existing windshield or accessories that may interfere with the installation.
4. Clean the installation area on the vehicle's roll cage and dashboard.

4.2. Attaching Brackets and Seals

1. Install Z-shaped Brackets: Attach the Z-shaped brackets to the roll cage using the provided M6x20mm screws and 9mm nuts. Secure them firmly.
2. Install L-shaped Brackets: Attach the L-shaped brackets to the lower part of the roll cage, ensuring they are aligned with the windshield's mounting points. Use M6x20mm screws, washers, and 9mm nuts, tightening with a hexagonal wrench and 10mm open-end wrench.
3. Apply Full-Length Seal: Carefully install the full-length rubber seal around the edges of the windshield panels to ensure a tight, weather-resistant fit.

4.3. Mounting the Windshield Panels

1. Position Upper Windshield: With assistance, carefully place the upper windshield panel onto the roll cage, aligning it with the previously installed Z-shaped brackets.
2. Secure Upper Windshield: Fix the upper windshield to the Z-shaped brackets using M6x20mm screws, washers, and 9mm nuts. Tighten securely.
3. Install Hydraulic Rods: Attach the hydraulic rods to the C-shaped brackets (if applicable for a flip-up feature) and connect them to the upper windshield panel using M6x20mm screws and 6mm nuts. Use a 12mm open-end wrench for the hydraulic rod connection.
4. Position Lower Windshield: Place the lower windshield panel onto the vehicle, aligning it with the L-shaped brackets.
5. Secure Lower Windshield: Install the lower windshield using M6x20mm screws, washers, and 9mm nuts. Ensure all connections are snug but do not overtighten until final adjustments are made.

4.4. Final Adjustments and Testing

1. Adjust Windshield Position: Adjust the windshield to the appropriate position, ensuring proper alignment and a tight seal.
2. Tighten All Screws: Once satisfied with the alignment, fully tighten all screws and nuts using the appropriate wrenches.
3. Remove Protective Films: Carefully tear off the protective films from both sides of the windshield panels.
4. Test Functionality: If applicable, test the operation of any flip-up or tilt-out mechanisms to ensure smooth movement and secure locking.

Figure 2: Front view of the Polaris Ranger 1000 Crew with the clear full glass windshield successfully installed.

Figure 3: Side view of the Polaris Ranger 1000 Crew showcasing the clear full glass windshield.

5. Operating Instructions

The Polaris 2891680 windshield is designed for fixed installation, providing continuous protection. If your specific model includes a tilt-out or flip-up feature (which may require additional components not included with the standard full glass windshield), follow these general operating guidelines:

• Tilt-Out Feature: To engage the tilt-out position, locate the release latches or handles, typically found on the lower corners of the windshield. Disengage the latches and gently push the windshield outward to the desired ventilation position. Secure it in place using the designated locking mechanism or support rods.
• Closing the Windshield: To close, release the locking mechanism and gently pull the windshield back into its fully closed position. Ensure the latches engage securely to prevent movement during operation.
• Visibility: Always ensure the windshield is clean and free from obstructions to maintain optimal visibility during vehicle operation.

6. Maintenance

• Cleaning: Clean the glass windshield regularly with a soft cloth and a non-abrasive glass cleaner. Avoid using harsh chemicals or abrasive materials that could scratch the glass or damage the seals.
• Inspection: Periodically inspect all mounting hardware, screws, and nuts for tightness. Re-tighten as necessary to ensure the windshield remains securely attached.
• Seal Integrity: Check the 360-degree gasket seal for any signs of wear, cracking, or damage. A compromised seal can lead to water or dust intrusion. Replace seals if damage is observed.
• Glass Condition: While the glass is shatterproof and scratch-resistant, inspect it for any chips or deep scratches that could affect visibility or structural integrity.

7. Troubleshooting

• Wind Noise or Leaks: If you experience excessive wind noise or water leaks, check the tightness of all mounting hardware and the integrity of the gasket seal. Ensure the windshield is properly seated and latched (if applicable).
• Difficulty Operating Tilt/Flip Feature: If a tilt-out or flip-up mechanism is stiff or difficult to operate, inspect the hinges and hydraulic rods for obstructions or damage. Apply a silicone-based lubricant to moving parts if needed.
• Vibration: If the windshield vibrates during operation, re-check all mounting points and ensure they are tightened to the recommended specifications.

8. Specifications

9. Warranty and Support

For specific warranty information and customer support, please refer to the documentation included with your purchase or visit the official Polaris website. Keep your proof of purchase for any warranty claims.