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Rhino Long Travel System 2008

Yamaha Rhino

FTR10079, FTR10013, FTR10080

4331 EUCALYPTUS AVE. ~~ CHINO, CA 91710

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Summary of Contents for FTR10013

Page 1: ...Rhino Long Travel System 2008 Yamaha Rhino FTR10079 FTR10013 FTR10080 4331 EUCALYPTUS AVE CHINO CA 91710 ...

Page 2: ...Lower Cntrl Arm w uni 2 FT95010 Upper Ball Joint Hat 1 FT95162G R Drv Rr Lower Control Arm 2 FT95019 Lower Ball Joint Hat 1 FT95163G R Pass Rr Lower Control Arm 2 FT95027 7 8 Mis Alignments 1 FT95234 Hdwr Sub Assembly Kit 4 FT95066 Mis Alignment 2 FT95079 Lower Ball Joint Mis Alignments FTR10013 Box 2 Shocks Steering 6 FTClamp Adel Clamp Qu a Part Description 2 FTLOCK Thread Locking Compound 1 FTR...

Page 3: ...24 C Lock Nut 2 3 8 USS Flat Washers 2 3 8 SAE Flat Washers 2 1 2 20 Jam Nut 2 10mm x 1 50 x 60mm Bolt Frt Lwr Shock Mnt 2 10mm x 1 50 C Lock Nut 4 10mm SAE Flat Washer 2 9 16 18 x 3 Bolt Upr Ball Joint Heim Joint 2 9 16 18 C Lock Nut 2 9 16 SAE Flat Washer 2 9 16 18 x 3 1 2 Bolt Lwr Ball Joint Uni Ball 2 9 16 18 C Lock Nut 4 1 4 20 x 3 4 Bolt Brake Line Tabs 4 1 4 20 C Lock Nut 8 1 4 SAE Flat Was...

Page 4: ...ERY FIRM RIDE IN THE FIRST FEW MILES OF OPERATION THIS IS NORMAL AND ONCE THE VEHICLE IS DRIVEN OVER S SHORT PERIOD THESE TIGHT TOLERANCES WILL LOOSEN SLIGHTLY ALLOWING THE VEHICLE S SUSPENSION TO OPERATE SMOOTHLY FOR OUTSTANDING PERFORMANCE PRIOR TO JACKING THE FRONT OF THE RHINO TO START THIS INSTALLATION MAKE SURE THAT THE ENTIRE STEERING ASSEMBLY STEERING WHEEL RACK PINION AND TIE ROD ASSEMBLY...

Page 5: ...the driver s side use a small center punch and a hammer and carefully lift the factory crimped section of the axle shaft nut from the axle shaft Remove the axle shaft nut and save SEE PHOTOS BELOW 3 Remove the two 10mm bolts that attach the brake line to the spindle and the upper control arm and save the hardware Remove the brake caliper and hang on the frame DO NOT LET THE CALIPER HANG BY THE BRA...

Page 6: ...d save the knuckle discard the hardware SEE PHOTO BELOW 5 Remove the shock assembly and discard save the hardware Remove the lower control arm and discard save the hardware SEE PHOTO BELOW 6 Remove the banjo bolt and brake hose from the caliper Re route the brake hose back through the upper a arm and re connect the hose to the caliper Re tighten the banjo bolt SEE PHOTOS IN NEXT COLUMN ...

Page 7: ...kit do so at this time 11 Locate the passenger front CV axle Carefully cut the factory boot clamps from the CV boots DO NOT CUT THE CV BOOT THEY WILL BE RE INSTALLED Starting with the inner CV slide the boot down the axle to access the inside of the CV First remove the large snap ring right at the base of the CV and pull the CV housing from the assembly Using a snap ring tool remove the small snap...

Page 8: ... into a vise with aluminum or soft jaws Use a soft brass or rubber mallet and carefully strike the outer CV downward to disengage the inner snap ring which holds the CV onto the axle USE CARE NOT TO DAMAGE THE CV OR CV HOUSING SEE PHOTOS IN NEXT COLUMN ...

Page 9: ... CV boot onto the axle and follow with the small snap ring one wire style onto the large splined end of new long travel axle Place the outer CV into a vise and LIGHTLY tighten enough just to hold the CV With the boot and C Clip installed insert the axle into the CV to where the clip makes contact with the CV Use a soft brass or rubber mallet and carefully strike the axle downward to engage the inn...

Page 10: ...e axle followed by the CV Cage tapered end on first If necessary use a soft brass or rubber mallet and carefully strike the CV cage downward to access the snap ring groove on the axle shaft Using snap ring pliers install the snap ring onto the end of the axle shaft SEE PHOTOS ON NEXT PAGE Tapered side of CV Cage ...

Page 11: ... overlaps at the crimp lock with a paint pen Remove the clamp from the boot and cut the excess from the strap Repeat this step for the other three clamps on this axle SEE PHOTOS BELOW 17 Using a CV boot band clamp tool clamp only the inner boot clamps Locate one of the supplied CV boot grease bags 4 bags are provided with this kit one for each axle half a bag for each CV Carefully pull back the bo...

Page 12: ...ware use supplied thread locking compound Leave loose SEE PHOTO BELOW 22 Install the passenger upper a arm with pre installed heim and jam nut into the factory a arm mounts and attach with the factory a arm hardware use supplied thread locking compound Leave loose SEE PHOTO BELOW IF YOU ARE INSTLLING THE HEAVY DUTY STEERING KIT DO SO NOW FOLLOWING THE INSTRUCTIONS PROVIDED WITH THAT KIT AND SKIP S...

Page 13: ...24 Locate the factory knuckle Remove the C clip retainer and then use a ball joint press and press out the lower ball joint from the knuckle Discard the ball joint and the C clip SEE PHOTOS BELOW ...

Page 14: ...ber mallet only if necessary SEE PHOTOS AND DIAGRAMS ON NEXT PAGE AND LAST PAGE FT95010 Upper Ball Joint Hat 27 Install the knuckle assembly onto the CV shaft Insert the supplied FT95027 7 8 mis alignment up into the bottom of the uni ball in the lower control arm and the FT95079 Mis alignment down into the top of the uni ball Then attach the knuckle to the lower control arm with the supplied 9 16...

Page 15: ...at and through the knuckle Place one of the supplied 3 8 SAE Flat Washers and one of the 3 8 USS Flat Washers on the bottom of the knuckle along with the 3 8 C lock nut Torque upper and lower control arm bolts to 32 lbs the 9 16 hardware to 95 lbs and the 3 8 hardware to 35 lbs use supplied thread locking compound Tighten the jam nut on the pre installed heim on the upper control arm SEE DIAGRAM O...

Page 16: ...the key way of the axle SEE PHOTO BELOW 30 Locate the 10mm brake caliper bolts and re attach the rotor Torque to 35 lbs use supplied thread locking compound Locate the two of the supplied adel clamps and hardware Position the adel clamps over the brake hose and attach to the tabs on the upper control arms Torque to 10 lbs SEE PHOTOS BELOW 1 3 8 USS Flat Washer 1 3 8 SAE Flat Washer ...

Page 17: ...re the front upper control arm mounts to the frame use a drill with a 5 16 drill bit and drill out to 5 16 Locate the supplied 5 16 hardware and attach the mount to the front of the frame and use a paint pen or center punch to mark the second hole Remove the mount and drill the second hole in to the frame Re install the bracket to the front of the frame and attach with the supplied 5 16 hardware I...

Page 18: ...se Clamps and position the shock reservoir onto the new mount as shown in photos and attach with the new clamps Position the reservoir so the hose does not make contact with the bottom side of the hood rotate twist the reservoir in the mount Do not over tighten the clamps or kink the reservoir hose SEE PHOTOS BELOW ...

Page 19: ...PPORTED VEHICLE Remove the rear tires 38 Rhino s equipped with the rear inner wheel well lip must be trimmed and flattened for maximum tire clearance during rear suspension travel Tilt the rear bed and use a paint pen and mark the front center and rear of the inner wheel well lip SEE PHOTO BELOW Bedside removed for photo only 39 Use a die grinder with a cut off wheel and cut the lip just flush wit...

Page 20: ...e radius to meet the existing front corner SEE PHOTOS BELOW Sand edges Apprx 4 Rear of Rhino Driver rear fender shown removed for photo only 41 Using an air saw carefully cut the fender following the mark Follow with a die grinder with a sanding disc to smooth out any rough edges or other imperfections 42 Working from the driver s side use a small center punch and a hammer and carefully lift the f...

Page 21: ...the sway bar end link from the lower control arm and save the hardware SEE PHOTOS ON NEXT PAGE Factory crimped section 44 Remove the upper control arm and save the hardware SEE PHOTO BELOW 45 Remove the shock assembly and discard save the hardware Remove the lower control arm and discard save the hardware SEE PHOTO IN NEXT COLUMN ...

Page 22: ...passenger long travel axle and install into the rear differential Use a large rubber mallet and tap the outer end of the axle shaft into the differential SEE PHOTO BELOW 50 Locate FT95006GR driver upper FT95162GR driver lower FT95008GR pass upper and FT95163GR pass Lower control arms FT95000 bushings FT95004 sleeves and the supplied bushing lube Place a small amount of lube into each of the barrel...

Page 23: ...ith the factory hardware Then attach to the upper control arm also with the factory hardware Torque upper and lower control arm bolts at the frame and at the knuckle to 32 lbs use supplied thread locking compound SEE PHOTOS ON NEXT PAGE 54 Locate and install the factory hub assembly onto the knuckle and axle shaft Install the factory axle shaft nut and torque to 190 lbs use supplied thread locking...

Page 24: ...stock upper mount with the factory hardware use supplied thread locking compound Torque the upper and lower shock bolts to 32lbs SEE PHOTOS ON NEXT PAGE SEE DIAGRAM ON LAST PAGE FOR PROPER MIS ALIGNMENT LOCATIONS Rear of Rhino Photo of passenger rear 56 Locate FT83178 Rear Resi Mount Bracket and FT86013 Hardware kit that is provided with the rear shocks NOTE some 2005 2006 model rhinos have a fact...

Page 25: ...enter punch to mark the two holes onto the back of the frame Use a drill with a 5 16 drill bit and drill out these two holes Re install the bracket to the INSIDE of the frame section and attach with the supplied 5 16 hardware Torque to 20 lbs SEE PHOTOS BELOW ON NEXT PAGE Photo of passenger rear Photo of passenger rear Mount on inside of the frame section Upper frame rail Rear frame section Photo ...

Page 26: ...e the stock plastic clip was located that held the factory brake line to the frame Using the factory hole and clamp the brake line with the supplied clamps 64 Refer to the owner s manual for the proper bleeding procedures of the brakes WARNING DO NOT DRIVE THE VEHICLE WITH OUT PROPER BLEEDING OF THE BRAKES 65 Repeat steps forty nine through fifty eight on the driver side 66 Check the fluid in the ...

Page 27: ...Upper and Lower Control Arm Knuckle New Tie Rod Assembly Knuckle ...

Page 28: ...plications or for racing purposes or for similar activities A RACE is defined as any contest between two or more vehicles or any contest of one or more vehicle against the clock whether or not such contest is for a prize This warranty does not include coverage for police or taxi vehicles race vehicles or vehicles used for government or commercial purposes Also excluded from this warranty are sales...

Page 29: ... parts are combined and or substituted with other aftermarket suspension products Combination and or substitution of other aftermarket suspension parts may cause premature wear and or product failure resulting in an accident causing injury or death Fabtech does not warrant products not manufactured by Fabtech Installation of Fabtech product may void the vehicles factory warranty it is the consumer...

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