Hitch Installation Tips

To ease reassembly, lift the RZR in the following fashion. Place a jack under the rear of the frame and raise the RZR until the tires are just barely off the ground.  Then, lower the jack slightly until the tires are just barely resting on the ground. When you remove the four radius rod bolts, the frame will not move since it is supported on the jack, and the tires will not move up or down since they are sitting on the ground. Now, when you go to reinstall the radius rod bolts you do not have to fight the weight of the wheels, tires and suspension to get everything realigned as you would if the tires were hanging in the air.  It is common for the tires to lean out a bit at the top after the radius rods are unbolted with the RZR supported in this fashion, but you can simply push the tire back into position and then easily push or pull on the upper radius rod with one hand to get it aligned perfectly while installing the radius rod bolt with the other hand. If things do move around a little more than normal, you can raise or lower the jack slightly to make it easier to align everything.

Reinstalling the radius rod nuts on the front side of the frame looks to be very difficult, or even impossible depending on the size of your hands.  When you removed the radius rods, you probably used a box wrench on the nut and a ratchet on the bolt.  The problem is, that a box wrench doesn't work very well to reinstall the nuts, as it tends to hold the nut crooked and not allow you to start the threads. Here's the trick. Place two small pieces of tape on the flats of an open-end wrench.  This will make it so that the wrench is snug when you slide the nut into the open-end wrench and the nut will not fall out. You will have the wrench going in at an odd angle to clear the frame and transmission, so angle the nut in the open-end wrench so that it looks to be at about the correct angle to be flush with the sheet metal of the frame.  You don't have to get this perfect, just close, as the nut will pivot between the flats of the open-end wrench and make itself flush with the frame when the nut contacts the frame. Install the radius rod bolt and get a couple threads started into the nut.  Now you can flip the wrench around and use the box end when tightening and torquing the radius rod bolt & nut.