3
1 full turn. Ensure bolts and nuts (13-14) are tightened securely with a hand wrench/spanner. Set/grub screws (2) must
be tightened ½ a turn after firm contact with the tube. U-bolts and nuts (11 and 12) in conjunction with Stiffener plate
(10) and the Upper Mounting Plate (7) should be tightened to the point where there is no slack left (the Upper Mount
Plate is stuff to move up or down with one finger on round tube) ; then tighten both nuts on each leg of the each U-
bolt a further 1 full turn to 1½ each.
The Aim
is to securely mount the Quadbar as close as possible to vertically (90
o
to the horizontal plane on the quad)
as shown above.
This also means
-For quad with a swing axle design, the Quadbar must be adjusted so that the
suspension can move through its
full travel
without interference of the Quadbar sliding bush with the main structure.
This is achieved by the vertical adjustment and the alignment of the bush to the Quadbar. Vertical adjustment in the
longitudinal direction is achieved by a) selecting the correct adjustment holes in the (5) bottom inner tube and b) the
orientation (forward or rearwards) of (15) Lower mounting plate. This will require some skill and thought. If the
adjustment requires the use of the lower holes in the bottom inner tubes (5) it will need to be removed and cut to an
appropriate length. Ensure it is absolutely necessary to cut prior to cutting and that at least 50mm -100mm of tube
remains above the hole that is to be used.
Tip:
change the orientation of (15) Lower mounting plate too achieve
adjustment before cutting.
I.
To Start:
Place quad on level flat surface.
II.
Upper Mount Assembly (A):
assemble 7,8,9,13,14 and tighten nuts (14) securely. Using the U-bolts (11) and
Nuts (12) with Stiffener Plates (10 round tube only), evenly secure the assembly loosely (nuts contact their
surfaces but not tight) to the rear cargo rack directly above the to hitch point. The most structurally sound
part must be used. For some models, an adaptor plate is available and must be used to connect the Upper
Mount Assembly to the frame of the quad.
III.
Lower Mount Assembly:
Place the lower mount plate (15) on top of the tow bar/ hitch and secure loosely
with bolt, washer and nut (16, 17, 18). Fit the small nylon bushes (6) into Bottom inner tube (5) and attach to
the lower mounting plate (15) with bolt and nut (19 & 20)
‘finger tight’
.
IV.
Main structure
: Insert the long end of main structure tube (3) up from below into the main nylon bush (9) and
slide the other end over the Bottom inner tube (5) and use bolt (21) to identify the correct adjustment hole
required. Insert the bolt (21) to secure the Main structure tube (3) too Bottom inner tube (5). Check that the
vertical alignment is correct and adjust using the holes and the orientation of the Lower mounting plate (15)
as described above. You may need to cut the Bottom inner tube (5) if needed to make use of the bottom holes,
ensuring there is at least 50mm of tube remaining above the hole. If in doubt, cut through the centre of the
upper most hole and refit, if more adjustment is required, cut off at the next hole down, and so on.
V.
Adjust to vertical:
Check and adjust so that the Quadbar is vertical, and on swing axle quads suspension, that
the full movement of the suspension without fouling of the main bush (7) on the main structure (manually
fully
move the suspension both down and up)
Don’t tighten bolts at this stage
.
VI.
Adjust the height
: Place the Flexi joint (1) over the Main structure (3) (the label-
“TOP REAR”
upwards and to
the approximate back/ rear direction) and insert the long end of the Upper structure (4) into the Flexi joint
ensuring they are both fully ‘home’
. The optimum height is between eye level and the top of the average
operators /
rider’s
head when seated in the normal operating position. Check the height of the top of the
Upper structure and measure the distance from the bottom of the Flexi Joint to the Main bush. The long end
of the Main structure (3) can be cut down to achieve the desired height, however there must be a minimum
of 75mm* and a maximum of 150mm from the bottom face of the Flexi Joint to the top face of the Main bush.
*Note that 80mm of the Main structure is inserted into the Flexi joint so 80+75= 155mm is the minimum
above the top of the Main bush.
Remove the Main structure (3) and trim as needed and reassemble.
VII.
Orientate the Flexi joint and the Upper structure (4).
Rotate the
Flexi joint (1)
on the main structure so the at
so that the two chamfered facers in the middle of the spring ends are facing rearwards. Orientate the bend in
Upper structure rearwards. Tighten as described above, the grub / set screws (2) to lock in position. For Quick
release modes; the Upper structure is removable, a bolt and collar is used to tighten it into position.
VIII.
Secure the main structure
: Evenly tighten, as described above, the Nuts (12) of the U-bolts (11) ensuring the
requirements of V. above are met. Tighten all bolts (16, 19, 21,) and nuts to their required tension as
described above
IX.
Recheck:
Go through all the details in this document in full including I -VIII above and check everything is
correct and tighten all bolts as required
X.
Fit protective foam:
tubing over the upper structure (4) [not shown].
XI.
Store safely the paperwork [Hand book] and advise the customer and future users or this document and the
details it contains
