installation instructions can-am

.

INSTALLATION INSTRUCTIONS

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COMMANDER 1000 LIMITED

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2

Kolpin Outdoors Inc. 205 N. Depot St.

Fox Lake, WI 53933

Tel: (920) 928-3118 www.kolpin.com

E-mail: [email protected]

SAFETY INSTRUCTIONS

Warning: Failure to heed all safety and operating instructions and warnings regarding use of this product can result in serious bodily injury.

READ PROPERLY COMPLETE ASSEMBLY INSTRUCTIONS BEFORE STARTING OF ASSEMBLY

Install all parts indicated in assembly instructions. Failure to fully assemble product before use could result in personal injury.

Assembly of product requires use of hand or power tools. If you are not experienced in using these types of tools,

have product dealer do the install for you.

Some parts contain sharp edges, wear protective gloves if necessary.

Always keep your assembly area clean, uncluttered and well lit.

Keep visitors and children a safe distance away from the assembly area. Visitors should wear the same safety equipment described under.

Never operate your UTV with the cab doors open. Failure to properly latch the

doors before moving the vehicle could result in serious injury.

Dress for safety. DO NOT wear loose clothing, gloves, neckties or jewelry if using power tools to assemble this product.

Insert all nut covers after you finish installation.

Never drive your UTV with the cab front window in open position. Failure of unproperly latched/locked the front window before driving

the vehicle could result in serious injury.

http://www.kolpin.com/

mailto:[email protected]

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MAINTANCE AND CLEANING

To clean polycarbonate surface use soapy water solution or other subtle means.

Dirt and dust wash by gently water stream and swipe only with wet or damp means in the direction from top to bottom.

The recommended frequency of cleaning of polycarbonate part

is about 1 time per month or according to the actual degree of pollution.

Do not use detergents that could scratch the surface plates. (abrasives, harsh fabrics, etc.)

Do not use solvents or alkaline detergents or cleaners with ammonia

(ammonium hydroxide).

Do not remove the impurities from the surface of the razor blades or other sharp items.

Do not clean cabine, when the polycarbonate plates are heated by the sun.

Do not use the squeegee, it could be scratched surface plates.

Do not clean the water current strength greater than 50 bar (WAP)

The manufacturer is not responsible for scratching the surface in case of failure to

comply with the above instructions.

All bolted connections of cab must be by user at regular intervals checked and tightened.



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TOOLS NEEDED Not included

Ratchet handle

Socket beg 19 mm

Socket beg 13 mm

(0,75 in)

(0,51 in)

Socket beg 10 mm

Socket beg 8 mm

Metric wrench 19 mm, 13mm and 10mm

(0,39 in)

(0,31 in)

Screwdriver philips

Screwdriver straight

Hex key 5, 6 and 8 mm



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Fox Lake, WI 53933



Utility knife

Drill ø 8mm

Drill ø 20-23mm

(0,31-0,33 in)

(0,79-0,91)

Isolating tape

clear OR black



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PREPARATION FOR INSTALLATION: Uninstall all additional systems from the roller cage (work lights, rear mirrors, drink holders etc.)

Uninstall all parts and assemblies of the original cab.

If you think, you need use our cab (probably in summer) without the doors, you can insert the side safety nets under the seats. Uninstall the side safety net’s upper screws (in red circles) and pull down the nets.

Save the safety net’s screw carefully, you need these later.



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View onto the save net under the seat.



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CAB PREVIEW LEFT FRONT VIEW

RIGHT REAR VIEW



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REAR PANEL Insert self-locking screws into the door base bottom holders.



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Place the left door base holder onto the UTV’s roller cage.



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Place the left door base onto the roller cage and onto the screws in the holder.



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Place the door base upper holder onto the door base and onto the roller cage.



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Fix the door base holder with the door base to the roller cage by nut, washer and nut cover. Tighten nut gently and repeat previous steps with right door base and holders.



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Place the left door hinge ledge onto the left door base.



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Fix the ledge with the door base by nuts, washers and nut covers.



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Adjust the door base to best position (pres it onto UTV’s the roller cage and onto the UTV’s body).



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Fix the ledge with the door base by screws, washers, nuts and nut covers. Tighten screws and nuts gently and repeat previous steps with right door base and ledge.



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Place the left rear side ledge with seal onto the left door base and onto the roller cage.



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Detail view to the ledge (ledge has blue colour in that picture only for your better orientation).



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Fix the side ledge with seal with the door base to the roller cage by nuts, washers and nut covers. Tighten nuts gently and repeat previous steps with the right door base and side ledge.



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Take out the safety films from the rear polycarbonate window and place the window onto the door bases and onto the rear side ledges.



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Fix the rear window with the rear ledges by screws, washers, nuts and nut covers on both sides.



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Place the rear bottom holder onto the rar window and onto the UTV’s body from inside of the cab.



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Fix the holder with the window and with the UTV’s body by screws, washers, nuts and nut covers.



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FRONT PANEL Place the front bottom ledge assembly onto the front roller cage and onto the front dashboard.



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Place the front bottom ledge holders onto the front ledge and onto the roller cage.



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Loosen bottom front original screws (left and right) from the UTV’s roller cage and fix the front ledge holders with the roller cage by screws on both sides.



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Fix the front bottom ledge with the ledge holders on both sides by screws, washers, nuts and nut covers. Press the ledge on to the dashboard and tighten sscrews and nuts hard.



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Place the hinge’s washers onto the front upper ledge and place the window assembly on hinge’s washers.



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Fix the hinges with the hinge’s washers and with the upper ledge by screws, washers, nuts and nut covers.



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Place the front upper ledge with the window onto the roller cage and onto the front bottom ledge.



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ROOF Place the roof onto the door bases, the rear window, the front upper ledge and the roller cage.



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Place the roof holders onto the roof and onto roller cage on both sides.



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Fix the roof with the roof holders and with the front upper ledge to the roller cage on both sides by screws, washers, nuts and nut covers. Don’t tighten these screws and nuts yet.



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Fix the roof with the rear window by screws, washers, nuts and nuts covers.

FRONT PANEL



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Adjust the roof and the front assembly to best position and tighten screws and nuts correctly.



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Take out the glass lock stoppers (red pins) from both glass lock .



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Connect the glass lock with the glass lock part in glass and insert the glass lock stops on both glass locks.



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Allow the glass lock holder’s srews and nut on both sides of the cab.



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Adjust the glass lock holders to best position (open and close the window few time) and tighten screws and nuts from previous page hard. If you lock the front window and you have some

gapes between the front glass seal and front bottom ledge, you cand adjust the pressure to the front glass seal by adjusting glass lock holders again to better position.



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Install the gas springs into the gas spring holders, be carefull to install gas springs in same position like in picture. When you install gas spring you maybe have to open the front window.



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Fix the gas spring with the bottom gas spring holder by nuts, washers and nut covers.



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Open the window and place the front upper ledge holders onto the roller cage and onto the front ledge.



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Fix the front upper ledge holders with the front upper ledge to the roller cage on both sides of the cab by screws, washers, nuts and nut covers. Tighten the screws and nuts hard.



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RIGHT+LEFT DOOR Lubricate the hinge’s pins and insert the door onto the hinge’s pins.



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Adjust the door to best position by hinge ledge and tighten hinge’s screws and nuts hard.



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Install the door stop assembly (pin, hook, washer and nut) with the door stop holder and tighten gently.



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Insert the door stop assembly into the inner door stop mechanism.



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Adjust the door stop assembly and the door stop holder to best position.



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Fix the door stop holder with the front ledge holder by nuts, washers and nut covers and tighten correctly. If you adjust the door stop corretly and close the door slowely, you can hear 2 clear metalic click.



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Place the gas spring holder onto the roof and onto the roller cage.



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Fix the gas spring holder with the safety net holder (in red circle) by original screw from page No.:6.



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Cut out the holes throught the roof upholstery (in red circles) in accordance with gas spring holder’s holes and drill holes ø8 mm (0,31-0,33 in) throught the roof.



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Fix the gas spring holder with the roof by screws, washers, nuts and nut covers.



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Place the gas spring onto the gas spring holder, be carefull to install gas springs in same position like in picture.



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Fix the gas spring with the gas spring holder by nuts, washers and nut covers.



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Uninstall screws and washers from the door (red and green arrows). Place the rear mirror and the mirror washer onto the door panel (blue arrows).

Fix the rear mirror and washer with the door by screws from previous step (green arrows).



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If you have gape between the rear bottom door seal and between the plastic body and you don’t have rear bottom door ledge installed use next steps.



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Uninstall screws and washers from the door and safe these carefully.



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Place the ledge between the door panel polycarbonate and the door frame.



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Install screws and washer from page No.: 59 and don’t tighten that.



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Adjust the door ledge onto best position and tighten screws.



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Cut the EPDM ledge to best shape.



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If you don’t have rear bottom door ledge, or you don’t want use that, you can stick self glued seal (red line) onto the UTV’S body in best position.



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If you have gapes between the door seal and between roller cage (red line), you can uninstall seat washer from the door. SEE NEXT PAGE



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Detail view onto the uninstalling.



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THE RIGHT DOOR INSTALLATION IS SIMILLAR WITH THE LEFT DOOR INSTALLATION



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ELECTROINSTALLATION Owerall wiring diagram



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Washer tube switch wiper/washer/off

Harness with washer tank



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Washer tank has be placed on the left outer wall after driver seat.

Take out the driver seat and the plastic covers from the driver under seat. Take out the washer tank holder ”Ω” (black) from the washer tank.



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Fix the washer tank holder with the rear wall by included screw, washers and nut.

Place the washer tank onto the washer tank holder and lead the harness throught the original hole.



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Lead the harness from washer tank to the UTV main fuse box.



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Uninstall the centrall UTV’s panel and save screws carefully.

Lead the harness No.:1 from the fuse box to the dashboard centrall tunnel.



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Take out the blind from the swith panel and cut bigger hole for included switch pull the harness branch No.: 1 throught the hole.

Connect the harness branch No.: 1 with the switch in accordance with the picture and insert switch in hole.

Insert the switch with connected harness into the hole and press gently to correct position.



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Drill hole ø20mm (red circle) into the dashboard.

Pull the harness branch No.: 3 throught the hole from previous page



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and lead the branch (red arrows) around the front left part of the roller cage.

Lead the branch (red arrows) from the left upper corner to the wiper motor arround the roller cage.

Uninstall the wiper motor cover from the wiper motor.



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Connect the harness branch No.: 3 with the wiper motor connector. And place the cover back.

Lead the harness branch No.:2 from the dashboard tunnel to the main electric box on the bottom side of the driver dashboard.



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Take out the original connector (in red elipse) from his position (NO CUT) and connect the harness branch No.: 2 with the original harness by included “thief” connectors.

Connect one red and one black wire from original harness with one red and one black wire from

wiper/washer harness. Don’t cut connectors from wiper/washer harness. You have to isolate the harness connectors by isolating tapes to prevent short circuits.

SEE NEXT PAGE



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Pull the washer hose from the wiper arm throught the bushing in the front upper ledge. Connect the harness washer hose with the wiper arm washer hose by washer tube.

Detail view to washer tube

Fill the washer liquide to the washer tank before first usage!



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It is absolutely necessary to bleed the air out of the UTV’s engine cooling system. Incomplete bleeding of cooling system can result in engine damage. If you don’t have

sufficient experience with this process, we strongly recommend professional service technician assistance.

We are not responsible for damages when cooling system bleeded incompletely. Please note that additional heater system will absorbed more than 2 liters of coolant fluid.

MAINTANCE AND CLEANING

To clean polycarbonate surface use soapy water solution or other subtle means.

Dirt and dust wash by gently water stream and swipe only with wet or damp means in the direction from top to bottom.

The recommended frequency of cleaning of polycarbonate part

is about 1 time per month or according to the actual degree of pollution.

Do not use detergents that could scratch the surface plates. (abrasives, harsh fabrics, etc.)

Do not use solvents or alkaline detergents or cleaners with ammonia

(ammonium hydroxide).

Do not remove the impurities from the surface of the razor blades or other sharp items.

Do not clean cabine, when the polycarbonate plates are heated by the sun.

Do not use the squeegee, it could be scratched surface plates.

Do not clean the water current strength greater than 50 bar (WAP)

The manufacturer is not responsible for scratching the surface in case of failure to comply with the above instructions.

All bolted connections of cab must be by user at regular intervals checked and tightened.



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TOOLS NEEDED Not included

Hole saw 46-52mm

Hole saw 76 mm

Ratchet handle

(1,81-2,0 in)

(3 in)

For tightening straps

Socket beg 8 mm

Screwdriver philips

Screwdriver straight

(0,31 in)

Utility knife

Isolating tape

Drill ø 2,5-4mm

clear OR black

( 0,1- 0,16 in)



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Drill ø 8mm

Drill ø 11,5-14mm

Drill ø 21mm

(0,31-0,33 in)

(0,45-0,55 in)

(0,83 in)

Drill ø 23,5-25,5mm

(1,0 in)



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HEATER Parts needed (included)

Heater with cover

Water pump

Electric vent

Tightening straps

Air vent

Hot air hose

Bigger and smaller

AL tape

Plastic rivets

Y couplings

Bigger and smaller



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El. Vent switch

Ventilator switch

Heater harness

assembly

Hot water hose

“Thief” connector

Pump harness



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IMPORTANT IT IS ABSOLUTELY NECESSARY TO TAKE OUT THE RUBBER PLUGS FROM THE HEATER TUBES!!!

Heater has been placed under the UTV’s dashboard near the glove box.



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Take out the seats from the UTV and uninstall the plastic covers from the sides of the central motor cover on both sides

View to driver side.



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Uninstall the glove box from the UTV dashboard.

Take out the glove box carefully.



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Take some photos of the harness and disconnect that.

View onto dashboard without the glove box (red ellipse for page No.: 13).



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Uninstall central UTV switch panel.

View onto the dashboard without the main panel.



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Stick the paper tapes onto the dashboard upper central plane.

Cut the holes ø76mm (3 in) into the dashboard in best position,



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be carefully to not interrupt any wires or hoses.

Cut the holes ø 46 -52 mm (1,81-2) in into the plastic wall in the inner upper corner of the dashboard. See page No.: 11 for better orientation.

Insert the air hoses into the heater air tubes and fix by AL tape.



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Connect the hot water hoses with the heater water tubes and fix by tightening straps. Cut the upper hose and install electric vent in same orientation like in the picture. Fix by tightening straps.

Drill 2 holes ø23,5-25 mm (0,93-1 in) into the plastic wall.



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Put the air hoses into the holes from page No.: 11 and lead these through the central tunnel to the holes in dashboard central plane.

Stretch the hoses through the holes and cut these to correct length.



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Insert the air vent with corner into the air hoses and fix by AL tape.

Press the air vents into the holes carefully.



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Connect the harness branch No.: 1 with the electric vent.

Connect the harness branch No.: 2 with the heater connector.



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Lead the hot water hose with electric vent ( do not change) from the heater to the bottom of the central tunnel through the hole (in red circle).

You can uninstall right front wheel for better access.



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Lead the hose from previous page through the UTV’s central tunnel to the left front wheel around original hose (with red arrow). Cut the heater hose to correct length (to thermostat in red circle).

Secure the original cooling system hose on vertical part by clamps or pliers and cut hose between pliers.



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Insert the tightening straps onto the original hose and install smaller “Y” couple. Insert the tightening strap onto the heater hose and insert the heater hose onto the “Y” couple. Tighten all straps very hard.

THERMOSTAT

ENGINE

HEATER



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Lead the second hot water hose through the second hole and through the central tunnel to the right front wheel on same way like the first heater hose and through the front space.

Lead heater hose (with red arrow) to the front right wheel. (On some pictures is view without the plastic body for your better orientation)



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Secure the original cooling hose by pliers or clamps and cut (red line) hose between the pliers.

Insert the tightening straps onto the original hose and install bigger “Y” couple in same orientation like in picture. Insert the tightening strap onto the heater hose and insert the heater hose onto the “Y” couple.

Tighten all straps very hard.

HEATER

ENGINE

COOLER



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Place the heater with the heater cover onto the plastic walls and make 4 marks onto the walls in accordance with the holes in the heater cover.

View to heater cover’s side

Take out the heater and drill holes ø 8 mm (0,31-0,33 in) into the mark’s centers.

Fix the heater cover with the UTV’s plastic walls by included plastic rivets.



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Lead the harness from the heater to the central tunnel around the original harnesses (in red circle).

Drill 1 hole ø 11,5-14mm (0,45-0,55 in) and 2 holes ø 2,5-4 mm ( 0,1- 0,16 in) into the dashboard in accordance with the ventilator switch base.

28

14



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View onto mounted switch base.

Drill whole ø 21 mm (0,83 in) into the dashboard for vent switch.



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Lead the harness (red arrow) from the central tunnel to the space under the driver dashboard.

Connect the harness branch No.: 3 with the ventilator switch body.



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Insert the switch body with the harness and with the serrated-lock washer into the prepared hole from page No.: 21(bottom picture) from inside. Place the switch base onto the

dashboard and onto the pin of the switch body.

Fix the switch with the switch base to dashboard by nut.

And place the plastic had onto the switch pin.



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Cut the heater hose near the bigger “Y” couple and insert the tightening straps onto the heater hose. Install the water pump into the hose in same orientation like in picture and tighten straps very hard.

Connect the pump connector with the pump. (Detail of connection)



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Lead the pump harness (red line) through the UTV’s central tunnel to the el. vent switch.

Connect the pump harness with the heater harness branch No.: 4 by “thief” connectors like in picture.



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Lead the harness branch No.: 4 through the hole for el. vent switch and connect these.

Insert the switch into the dashboard.

Lead the harness branch No.: 5 under the driver dashboard from the switches to the main UTV’s fuse box.



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If you don’t have installed wiper/washer harness connect the harness branch No.: 5 by the “thief” connectors (red wire with the red wire and black with black see next pictures).

If you have installed wiper/washer harness use “thief” connectors (included) and connect one red and one black wire from heater harness with one red and one black wire from wiper/washer harness.

Don’t cut connectors from heater harness. You have to isolate the harness connectors by isolating tapes to prevent short circuits.

Now you can install back right front wheel.

SEE NEXT PAGE



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It is absolutely necessary to bleed the air out of the UTV’s engine cooling system. Incomplete bleeding of cooling system can result in engine damage. If you don’t have

sufficient experience with this process, we strongly recommend professional service technician assistance.

We are not responsible for damages when cooling system is bleeded incompletely. Please note that aditionall

heater system will absorbed more than 2 liters of coolant fluid.

BLEEDING OF THE COOLING SYSTEM

1. Important: After the heater system installed check the system for leaks. 2. Fill the correct cooling liquid into the cooling circuit to full level. It is necessary

to check and add cooling liquid into the cooling circuit after every next step. 3. During next operations is necessary to always check cooling system

temperature. If one part of the cooling system is cold and other is hot, bleeding is not correct. Turn engine off and let it cool down. Don’t start engine again before is not cold.

4. Lift up the front part of the UTV about 2 foot high (60 cm) for 3 minutes. At this period start the UTV engine, press accelerator few times and turn engine off. Don’t leave engine running during this operation longer then 1 minute.

5. Put down the front part of the UTV. 6. Lift up the left part of the UTV about 2 foot high(60 cm) for 3 minutes. At this

period start the UTV engine, press accelerator few times and turn engine off. Don’t leave engine running during this operation longer then 1 minute.

7. If the cooling system bleeding was done correctly, you can continue to next steps. If not, repeat previous steps again until the system is perfectly bleed out.

8. Turn on the electric valve/booster pump switch - green and repeat the steps No.:4,5, 6 and 7. Be still aware of steps no.: 2 and 3 and pay always special attention to the cooling system temperature .

SEE NEXT PAGE



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Now you can install back all plastic covers, glove box and central UTV’S switch panel.

It is important to check the coolant level regularly at least 4-5 times during the first several days of operation and fill as necessary until the coolant level has stabilized. The heater will draw and retain coolant, sometimes at the expense of coolant to the engine. This can cause engine overheating if not managed properly.



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