Related Manuals for Fabtech FTR10079
Summary of Contents for Fabtech FTR10079
- Page 1 Rhino Long Travel System 2008 Yamaha Rhino FTR10079, FTR10013, FTR10080 4331 EUCALYPTUS AVE. ~~ CHINO, CA 91710...
- Page 2 909-597-7800 Fax 909-597-7185 www.fabtechmotorsports.com Rhino Long Travel System FTR10079, FTR10013, FTR10080 2008 Yamaha Rhino FTR10079 Box 1 (Arms) FT95234 Hardware Sub-Assembly Part # Description Part # Description FT95006G 2500000505 Drv Rr Upper Control Arm 1/4" SAE Flat Washer FT95008G 2520000305 Pass.
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Page 3: Tool List
O.E.M. WHEELS & TIRES CAN BE REINSTALLED WITH THIS KIT. FABTECH RECOMMEND’S A 12”x7” WHEEL WITH A 5+2 OFFSET WITH A 26”x 9”x 12”TIRE IN FRONT AND A 12” x 10” WHEEL WITH A 5 + 5 OFFSET WITH A 26”x 12”x12” TIRE IN THE REAR (may require minor trimming) www.fabtechmotorsports.com... - Page 4 CHECK ALL PARTS INCLUDED IN THIS KIT TO THE PARTS LIST ABOVE BEFORE BEGINNING INSTALLATION OF THIS KIT. IF ANY PARTS ARE MISSING, CONTACT FABTECH AT 909-597-7800. DO NOT ALTER THE FINISH OF THESE COMPONENTS, EXAMPLE- CHROMING, ZINC PLATING OR PAINTING.
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Page 5: Installation Instructions
INSTALLATION INSTRUCTIONS: 1. Disconnect the negative terminal on the battery. With the Remove the brake caliper and hang on the frame. DO NOT Rhino on level ground, set the emergency brake and block LET THE CALIPER HANG BY THE BRAKE HOSE. the rear tires. - Page 6 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 4. Remove the cotter pins in the outer tie rod end and the upper and lower ball joints and discard.
- Page 7 7. Remove the upper control arm and save the hardware. SEE 9. Repeat steps two through eight on the passenger side PHOTO ON NEXT PAGE 10. If you are installing the optional weld on gusset kit, do so at this time. 11.
- Page 8 Large snap ring (one-wire style) 12. Place the CV axle 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.
- Page 9 13. Locate FT95074 Front Long travel Axle, FT95060 Clamp Kit with Snap Rings, and the factory outer CV and Boot. Open the clamp and snap ring kit and the factory snap rings which were just removed. Match the old snap rings to the new ones in the kit (provided FT95060 kit has snap rings for all EIGHT CV’s).
- Page 10 14. Locate the Factory inner CV and internal parts, CV Boot, and new supplied snap ring. Install the CV boot onto the 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.
- Page 11 and axle. Pull the clamp tight around the boot and mark the clamp where it 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 Mark &...
- Page 12 18. Repeat steps eleven through seven-teen for the driver side 22. Install the passenger upper a-arm with pre-installed ¾” heim CV axle. and jam nut into the factory a-arm mounts and attach with the factory a-arm hardware. (use supplied thread-locking 19.
- 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 25. Place the knuckle into the vise with aluminum or soft jaws and use care not do damage. Use a drill with a ¾” drill bit and drill out the knuckle at the upper ball joint location and at the tie rod location. SEE PHOTOS BELOW FT95010 Upper Ball Joint Hat FT95021...
- Page 15 Upper and Lower Control Arm @ Knuckle New Tie Rod Assembly @ Knuckle 28. Locate FT95020 ½” Short Mis-alignment and the supplied 3/8” x 3 ¼” hardware. Insert the mis-alignment into the top FT95020 of the ½” heim in the new extended steering shaft followed ½”short mis- by the 3/8”...
- Page 16 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 ¼” hardware. Position the adel clamps over the brake hose and attach to the tabs on the upper control arms. Torque to 10 lbs.
- Page 17 31. Locate FTR60138 Front Shock, provided shock mis- alignments, and the factory shock hardware. Insert the mis- alignments into the top of the shock and mount into the stock upper mount with the factory hardware. Insert the mis- alignments into the heim on the bottom of the shock. Mount the bottom of the shock to the upper control arm mounts with the SUPPLIED 10mm x 1.50 x 60mm bolts and hardware.
- Page 18 33. Locate FT89028 Hose 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 34. Repeat steps nine-teen through thirty-three on the passenger side. 35. Check the fluid level in the brake reservoir and add as necessary. Bleed the brake system as per the manufacture’s specification. See owners manual 36. Install tires and wheels and torque lug nuts to wheel manufacturer’s specifications.
- Page 20 40. Next, the flared portion of the rear wheel well needs to be trimmed for adequate tire clearance during rear suspension travel. Apply masking tape to the lower 4” of the entire flared portion of the fender. Starting from the rear, mark a 1 ½”...
- Page 21 Factory crimped section 44. Remove the upper control arm and save the hardware. SEE PHOTO BELOW 43. Remove the upper and lower knuckle assembly hardware and remove the knuckle assembly. Save the knuckle and the hardware. Remove the sway bar end link from the lower 45.
- Page 22 47. If you are installing the optional weld on gusset kit, do so at this time following those included directions. 48. Repeat steps eleven through seven-teen for rear CV axle assembly. SEE DIAGRAM ON LAST PAGE OF INSTRUCTIONS FOR CORRECT CV AXLE IDENTIFICATION.
- Page 23 52. Install the passenger upper a-arm into the factory a-arm mounts and attach with the factory a-arm hardware. (use supplied thread-locking compound) Leave loose. SEE PHOTO BELOW 53. Locate the factory knuckle assembly and hardware. Position the assembly onto the CV shaft and attach to the lower control arm with the factory hardware.
- Page 24 55. Locate FTR60141 Rear Shock, provided shock mis- alignments, supplied (4) 7/16” washers, and the factory shock hardware. Insert the shorter mis-alignments into the heim on the bottom of the shock. Mount the bottom of the shock to the lower control arm mounts with the shock reservoir facing to the rear of the Rhino with the factory hardware with 2 of the supplied 7/16”...
- Page 25 attach the mount to the back 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 INSIDE of the frame and attach with the supplied 5/16”...
- Page 26 58. Rotate the rear sway bar to connect the end link to the tab on nuts, ¼” washers and attach the brake line to the lower arm the new lower control arm using the factory hardware. tabs. SEE PHOTO ON NEXT PAGE. Torque to 32 lbs.
- Page 27 Upper and Lower Control Arm @ Knuckle New Tie Rod Assembly @ Knuckle...
- Page 28 It may increase the vehicle’s susceptibility to a rollover, on road and off road, at all speeds. Extreme care should be taken to operate the vehicle safely at all times to prevent rollover or loss of control resulting in serious injury or death. Fabtech front end Desert Guards may impair the deployment or operation of vehicles equipped with supplemental restraining systems/air bag systems and should not be installed if the vehicle is equipped as so.
- Page 29 Installation of Fabtech product may void the vehicles factory warranty; it is the consumer’s responsibility to check with their local vehicle’s dealer for warranty disposition before the installation of the product. It is the responsibility of the distributor and/or the retailer to review all warranties and warnings of Fabtech products with the consumer prior to purchase.