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2024 Polaris XPEDITION Front Skeleton Doors Installation

This video goes over the installation of the Front Skeleton Doors (part number 2884717).

Required Tools and Supplies

  • T15 TORX® Socket
  • T30 TORX® Socket
  • T40 TORX® Socket
  • 10mm Socket
  • 13mm Socket
  • 10mm Wrench
  • Ratchet
  • Torque Wrench
  • Pry Tool
  • Multifunction Pliers
  • Eye Protection
  • Nitrile Gloves
  • Shop Rags

For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when installing accessories on your Polaris XPEDITION.

To install the Front Skeleton Doors on your Polaris XPEDITION XP or ADV, follow these steps:

1. Park the vehicle on a flat, level surface, ensure the vehicle is in PARK and remove the key.

2. Release the two quarter-turn latches on the grill.

3. Pivot the grill forward and lift out to remove from the vehicle.

4. Release the two rubber straps securing the hood.

5. Pivot the hood up and slide forward to remove from the vehicle.

6. To remove the outer A-pillar trim panel, remove and retain the three screws from the inner panel.

7. Remove and retain the push-pin rivet from the rear of the panel. Note: If the vehicle is equipped with a full or half door, the door must be fully opened to remove or install the outer sail panel.

8. Pull the panel outward and pull toward the front of the vehicle to remove the panel. Repeat on the other side.

9. Remove the front fender by retaining four push-pin rivets with a multifunction pliers.

10. Remove and retain two screws with a T30 TORX® and T40 TORX®.

11. Pull the fender outward to disengage the upper tabs.

12. Turn the fender and lift to disengage the lower tab and remove.

13. To remove the front half-door, find the bracket and the limit strap on the A-pillar.

14. Remove two screws and the limit strap bracket from the rear of the A-pillar with a 10mm socket.

15. Close the door and engage the door with the striker. This will help support the door while the hinge screws are removed. Caution: Doors are large and may weigh up to 60 lbs/27 kg. Use assistance when lifting and moving doors, if necessary.

16. Remove the four hinge screws with a 13mm socket.

17. Pull the door handle to disengage the striker and lift the door away from the vehicle. Repeat on other side.

18. Set the door on a flat surface with the outside facing down. Caution: Protect painted/plastic surfaces with protective cloth/tape during removal or installation.

19. Remove the half door hinge, remove and retain four screws from the door and two door hinges with a 13mm socket.

20. Remove and retain two screws and limit strap bracket from inside of the door with a 10mm socket. Repeat on the other side.

21. To prepare the skeleton door, install the hinges and four screws with a 13mm socket. Torque screws to 26 ft-lbs (35 Nm).

22. Install two screws, two nuts and the limit strap bracket with a 10mm wrench. Torque screws to 106 in-lbs (12 Nm). Repeat on the other side.

23. To install the front doors, place in the door in the opening and engage the striker with the door latch to help support the weight of the door.

24. Loosely install the four door hinges. Do not torque at this time.

25. To adjust the front doors, inspect the outer edges of the door and make sure the gaps are even on the rear side and the bottom of the door. When the door is properly positioned, use a 13mm socket to torque hinge screws to 26 ft-lbs (35 Nm).

26. After the door is properly positioned, check engagement with the striker and adjust the striker up or down as needed for proper latching. (If the door does not seal or rattles when latched, adjust the striker inward. If the door is difficult to open, adjust the striker outward.) Remove the striker cover to access the striker screws.

27. When finished adjusting the striker with a 10mm socket. Torque striker screws to 26 ft-lbs (35 Nm) and replace the cover.

28. Thread the bracket through the limit strap and install with two screws to the A-pillar with a 10mm socket. Torque bracket screws to 106 in-lbs (12 Nm).

29. To reinstall the front fender, put the tab into the opening and turn the top of the trim toward the vehicle.

30. Push the fender inward to engage the upper tabs.

31. Install two retained screws, and torque the front (M6) to 40 in-lbs (4.4 Nm) and the rear (#14) 30 in-lbs (3.4 Nm).

32. Install four push-pin rivets.

33. To reinstall the sail panel, put the front edge of the sail panel in place and push the panel inward and turn toward the rear.

34. Install the inner panel and three screws. Torque screws to 22 in-lbs (2.5 Nm).

35. Install a push-pin rivet.

36. To reinstall the hood, put the tabs on the hood through the opening in the under-hood liner.

37. Lower the hood into position and pull the rubber straps down over the hooks.

38. To reinstall the grill, put the tabs on the grill through the openings in the front fascia and push the top of the grill into the correct position.

39. Push each stud in and turn one-quarter turn clockwise to secure the grill.

40. When hinges are removed from the half doors, the hinge nut plate inside of the door will be loose and could fall out of place. If hinges are to be reattached to the half doors, it will be necessary to remove trim panels from the door. With the trim panels removed, the hinge nut plate can be located and replaced in the proper position.

41. To remove the front door trim panel on multi-passenger vehicles, set the door on a flat surface with the outside facing up using a pry tool.

42. Remove and retain the handle cover by prying up the cover.

43. Remove and retain the screw to separate the handle from the actuator with a T15 TORX®.

44. Lift the handle away from the actuator and pull backwards to remove the handle. Keep the handle for later installation.

45. Remove and retain the four push-pin rivets from the front of the door.

46. Remove and retain the four push-pin rivets from the rear of the door.

47. Move the panel toward the rear and lift to remove the panel. Keep the panel for later installation.

View the instructions for this kit by searching the Polaris Accessory Installation Instruction Site.
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.

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© 2024 Polaris Industries Inc.