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Rhino Long Travel System

FTR10079, FTR10013, FTR10080

2008 Yamaha Rhino

FTR10079

Box 1 (Arms)

FT95234 Hardware

Sub-Assembly

a Part

Description

a Part

Description

FT95006G
R

Drv Rr Upper Control Arm

2500000505

1/4" SAE Flat Washer

FT95008G
R

Pass. Rr Upper Control Arm

2520000305

1/4"-20 Nylock Nut

1 FT95024 Hardware

Kit

2520100105

1/4"-20 x 1" Hex Cap Bolt

FT95067G
R

Drv Frt Upper Control Arm

w/heim

2 FTR10079i Instruction

Sheet

FT95068G
R

Drv Frt Lower Control Arm

w/uni

FT95000

Control Arm Bushing Half

FT95069G
R

Pass. Frt Upper Ctrl Arm

w/heim

FT95001

Control Arm Sleeve

FT95070G
R

Pass. Frt Lower Cntrl Arm

w/uni

FT95010

Upper Ball Joint Hat

FT95162G
R

Drv Rr Lower Control Arm

FT95019

Lower Ball Joint Hat

FT95163G
R

Pass. Rr Lower Control Arm

FT95027

7/8" Mis Alignments

FT95234

Hdwr Sub-Assembly Kit

FT95066

Mis-Alignment

FT95079

Lower Ball Joint Mis-Alignments

FTR10013

Box 2 (Shocks & Steering)

6 FTClamp

Adel

Clamp

a Part

Description

FTLOCK

Thread Locking Compound

FTR60138

Front Shock w/ Mounting Hardware

FTLUBE

Lube

FTR60141

Rear Shock w/ Mounting Hardware

FT95015

Tie Rod End Extension

FTR10080

Box 3 (Axles)

FT95023

1/2" x 1/2" Heim

a Part

Description

FT95020

Mis-Alignment 1/2" Heim (Short)

FT95165

Front Drv / Pass Long Travel
Axle

FT95021

Steering Arm Hat w/mis-alignment

FT95166

Rear Driver Long Travel Axle

FT95167

Rear Passenger Long Travel
Axle

FT95060

Boot Clamp Kit W/Snap Ring

FT95065 Grease

Pack

FT95161

Rear Brake line

Содержание FTR10079

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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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