Gorilla Axle 7”-4” Adjustable Suspension Lift 2004

Gorilla Axle 7”-4” Adjustable Suspension Lift
2004-2008 Yamaha Rhino 450/660/700
www.gorilla-axle.com
318.345.8186
[email protected]
PRODUCT SAFETY WARNING
Read before installation!!
Installation of suspension lift kits will raise the center of gravity. For this
reason, Gorilla Axle Inc. strongly urges that extreme caution is used when
encountering potentially hazardous driving conditions such as hill climbs, side
hills, or traversing deep ruts and mud pits. Also, the driver’s field of vision and
judgment will not be as good due to the elevated ride height. The installation
of larger diameter tires will cause the speedometer to read slower than the
actual true ground speed in addition to affecting braking performance which
may alter the predicted stopping distance needed.
It is the owner’s
responsibility to caution and warn any potential driver of the vehicle about these
driving and handling conditions. Wider tires and wheels are suggested to help
accommodate the lifted ATV/RUV and offer more stability. Gorilla Axle Inc.
strongly recommends the use of helmets AT ALL TIMES. It is strongly
suggested that a qualified professional mechanic install all Gorilla Products as to
insure correct installation. Do not add, alter, or fabricate any factory or
aftermarket products to add height to the intended lift of the Gorilla Lift Kit.
Doing this could result in product malfunction, injury, death or loss of warranty.
Do not jump or exceed speeds over 25mph. Gorilla Axle Inc. will not be held
liable or responsible for damages or personal injuries resulting from the use of
lifted ATVs, altered products, improper installation, or improper use of lifted
ATVs. Review your parts list for missing or damaged parts. Please call us at
318.345.8186 with any questions concerning product design, function, or the
correct usage.
When possible, keep all bolts uniform for a clean appearance.
DO NOT TIGHTEN ANY BOLTS UNTIL INSTALL ON LIFT IS COMPLETE.
Parts List
GFRA-U
Front Right Upper A-Arm
GFRA-L
Front Right Lower A-Arm
GRRA-L
Rear Right Lower A-Arm
GRRA-U
Rear Right Upper A-Arm
GFLA-U
Front Left Upper A-Arm
GFLA-L
Front Left Lower A-Arm
GRLA-L
Rear Left Lower A-Arm
GRLA-U
Rear Left Upper A-Arm
GRP-R
Gorilla Rack & Pinion (Boot)
GBJP-R
(1) Gorilla Ball Joint Plate
Bolt Kit
WARNING LABEL-APPLY TO DASH
GFSM
Front Shock Mount Bar
GFSM P
(4) Shock Mount Plates
GTR-R
Heavy Duty Tie Rod Right
GTR-L
Heavy Duty Tie Rod Left
GRSM-A
Right Rear Shock Mount-Front Plate
GRSM-B
Right Rear Shock Mount-Back Plate
GRSM-C
Left Rear Shock Mount-Front Plate
GRSM-D
Left Rear Shock Mount-Back Plate
GRP-L
Gorilla Rack & Pinion (Boot)
GBJP-L
(1) Gorilla Ball Joint Plate
(4) Gorilla Lift Axles (Gorilla Axle should be legible)
*********NOTICE*************
This lift must be operated at the 4” setting for 15 hours for initial break in period before operating at the 7”
setting.
******This Suspension Lift is adjustable to operate at the 4” Setting or the 7” setting. Do not attempt to
operate at 4” front and 7” rear or in any other combination. This will void the warranty, damage the vehicle
and could cause injury to driver and passenger. ********
*******When adjusting from 7” to 4” suspension replace locknuts on bolts.*****
SOME CUTTING REQUIRED!
A
FRONT ASSEMBLY
Remove Wheel, Wheel Hub, Front Shock, A-Arms & Tie Rods.
A-1. Remove Right Side front wheel and wheel hub. For ease of install place hub out of way
using Wire ties or mechanics wire. Leave Brake Lines attached.
A-2. Remove Front Shock Assembly, Upper A-Arm, Front Axle and Lower A-Arm.
A-3. Remove Tie-Rod assembly. Remove boot off of Rack & Pinion. Remove R & P and install
GRP-R and new R & P boot.
A-4. Repeat Steps A-1-3 for Left Side.
A-5. Remove all Ball Joints from Stock A-Arms and install in Gorilla Lift A-Arms. Apply LockTight on ball joint threads for secure fit. Do not use Stock clip on Front Upper A-Arms. Use
provided Ball Joint Lock Bracket on top ball joint. Apply Lock-Tight to bolt and tighten.
A-6. Cut or Grind away Frame rail for front inner boot clearance. This will not reduce frame
structure or compromise the vehicles stability. See picture.
B
Install Gorilla Front Shock Mount Extender
B-1. Remove plastic rivets inside shock frame rails between stock shock mounts. Install 32”
square tubing (GFSM) inside frame rail. Attach (2) GFSMP to GFSM using 2 ½ bolts (supplied).
See Pictures.
B-2. Insert 2 ½ bolt(supplied) through GFSM and stock shock mount hole.
B-3. Repeat for Left Side.
DO NOT TIGHTEN BOLTS UNTIL LIFT IS COMPLETE.
C
Install Heavy Duty Tie Rods.
C-1. Install Heavy Duty Tie Rod (GTR-R) to GRP joint. Use stock outer Tie rod ends and stock
jam nut.
C-2. Repeat step C-1 for Left Side. (GTR-L)
DO NOT TIGHTEN BOLTS UNTIL LIFT IS COMPLETE.
D
Install A-Arms, Axle’s, Shocks, & Wheel Hub.
Use Stock bolts for all front A-Arms
D-1. Install front Right Lower A-Arm (GFRA-L) using stock bolts and nuts. Attach bottom of
Wheel Hub to Lower A-Arm using stock bolts.
D-2. Install Front Gorilla Axles. (See directions in axle box)
D-3. Install Outer Joint of Gorilla Axle in Wheel Hub. Install upper A-Arm (GFRA-U) using
stock bolts and nuts. Attach Upper A-Arm to ball joint and attach GBJP to bottom of ball joint.
Apply LockTite to bolt and tighten. Attach Tie Rod end to Wheel Hub using stock nut.
D-4. Install Bottom of shock assembly to Lower A-Arm. Attach upper shock assembly to Front
Shock Mount plate on 7” Setting. (GFSMP)
D-5. Tighten all bolts.
D-6. Install Wheel and tighten Lug Nuts.
E
REAR ASSEMBLY
Remove Wheel, Wheel Hub, Rear Shock, A-Arms & Sway Bar
E-1. Remove Right Side Rear Wheel and Wheel Hub.
E-2. Unbolt Sway Bar from Lower A-Arm and Remove from ATV/RUV.
E-3. Remove Rear Shock, and A-Arms. Remove Rear Axles.
F
Install Rear Shock Mount Plates, A-Arms, Hubs & Axles
F-1. Right Rear. Install Lower Rear A-Arm (GRRA-L) using stock bolts. Place Outer Joint
through Rear Hub, attach Spindle and attach Axle Nut. Do not tighten axle nut.
***NOTE*** Rear Hub is Directional*** Repeat on Left Side.
F-2. Install rear Axles. See instructions in Axle box.
F-3. Right Rear. Install GRSM-A, GRSM-B and GRRA-U using stock bolts. See Pictures.
Repeat on Left Side.
F-5. Install Upper A-Arm (GRRA-U) using supplied bolts. Attach Rear Hub to Upper A-Arm
Using bolts, supplied washers and attach lock nut. Repeat on Left Side.
F-6. Install Lower Shock Assembly to Lower A-Arm (GRRA-L) using supplied bolts and nuts.
Install upper Shock Assembly to Shock Mount (GRSM-A & GRSM-B) using Bolts and washers
on softest setting. Attach lock nut. Repeat on Left Side.
TIGHTEN BOLTS AND LIFT IS COMPLETE.
TEST RIDE
Perform a test ride at slow speeds to insure all parts are installed correctly.
Re-inspect all bolts and nuts are tight. Repeat this procedure every 30 days or 50 miles to
insure the RUV Suspension is being maintained.
G
Adjust your Suspension to 4” setting.
G-1. Place a jack under the rear of the RUV and pick tires up slightly off the ground. Unbolt at
the 7” shock setting and place bolt in the 4” setting. Replace with NEW lock nuts on bolts and
tighten. Lower RUV to ground. Rear is complete.
G-2. Jack front of RUV up and remove outer bolt on 7” setting. Loosen inside bolt on 7”
setting. Lower RUV and align holes in shock mounts on 4” setting. Place bolt through holes
and attach NEW locknut on bolt. Tighten inner and outer bolts. Lower RUV to ground.
TEST RIDE
Perform a test ride at slow speeds to insure all parts are installed correctly.
Re-inspect all bolts and nuts are tight. Repeat this procedure every 30 days or 50 miles to
insure the RUV Suspension is being maintained.
See pictures at
http://www.gorilla-axle.com/gallery/main.php?g2_itemId=3991