background image

 

 

7.

 

Remove the upper control arm and save the hardware. SEE 
PHOTO ON NEXT PAGE 

 

 

 

8.

 

Remove the axle CV shaft from the front differential and 
with a paint pen, mark on the inner and outer CV’s and axle 
where they were removed from (drv front inner / drv. front 
outer).  The CV’s and axle shafts are front and rear / inner 
and outer specific. They MUST go back into the proper 
locations. SEE PHOTO BELOW 

 

 

 

9.

 

Repeat steps two through eight on the passenger side 

 
10.

 

If you are installing the optional weld on gusset 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,

 s

lide 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 ring 
from the end of the CV shaft. Carefully remove the CV cage 
from the axle shaft making sure not to loose any of the CV 
balls. Remove both of the CV boots and save with all of the 
clips and internal parts, discard the old CV boot clamps. 
SEE PHOTOS IN NEXT COLUMN AND PAGE 

 

 

Do not damage 

CV boot 

 

Summary of Contents for FTR10079

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

Page 2: ...ower 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 H...

Page 3: ...4 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 Join...

Page 4: ...RY 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 OPER...

Page 5: ...he 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 Re...

Page 6: ...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...

Page 7: ...it 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 th...

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 DA...

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 C...

Page 10: ...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...

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 boo...

Page 12: ...are 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...

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: ...er 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 alignm...

Page 15: ...t 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 a...

Page 16: ...he 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 a...

Page 17: ...e 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 pai...

Page 18: ...e 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...

Page 19: ...PORTED 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...

Page 20: ...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 m...

Page 21: ...he 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 th...

Page 22: ...assenger 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 uppe...

Page 23: ...th 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 locki...

Page 24: ...tock 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 ALIGNMEN...

Page 25: ...nter 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 th...

Page 26: ...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...

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

Page 28: ...lications 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 con...

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 r...

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