00-06 TRX350 Rancher

Kit No. XTH350

 

Read these instructions carefully. Xtreme recommends, a professional mechanic perform the installation. Care should be taken to follow all standard safety procedures.

 

A thorough inspection of the suspension should be made prior to performing the installation. Any worn, bent or broken parts should be replaced. After installation another inspection should be made, checking for loose components or missing hardware. Inspect, again after eight hours of operation.

 

To begin, check to make sure all components and necessary tools are on hand.

 

Components:

The kit consists of three bags containing Hardware and Brackets.

Bag #1 for the Left Front

Bag #2 for the Right Front

Bag #3 for the Rear

 

See the attached sheets for a complete breakdown.

 

Disassembly / Installation Procedure

 

1.)Begin by loosening the lug nuts on both front tires. Raise the unit, using a suitable

lifting device or procedure, until the front tires are off the ground. If using a floor jack

with stands, chock the rear wheels to prevent the unit from rolling. If using jack

stands, make sure the stands are placed under the frame and not the body. Make sure

the unit is stable and secure.

 

2.)Remove the tires / wheels.

NOTE: Now is a good time to check the threads on the lug studs. Check for rust, pulled threads or other deterioration that could cause a stud/thread failure.

 

3.)Remove contents from Bag #1. This bag is for the drivers left front wheel. Looking at

the assembly sheet for bag #1 follow these instructions. Remove the lower shock

attaching bolt. Slide one of the XTH350-03 brackets on a 10x55mm bolt. Be sure

bolts install as per diagram. Insert the XTH350-08 spacer into the stock shock mount,

insert the 10x55mm bolt through mount and spacer. Install the other XTH350-03

bracket and tighten the nut finger tight. Do not tighten. Take the other 10x55mm bolt

and insert it into the XTH350–03 bracket installing a 10mm washer as shown in the

diagram. Install two more 10mm washers, the XTH350-03 bracket and start the 10mm

nyloc. Tighten finger tight. Install the XTH350-01 and snug up the ¼ inch flange

nuts. Remove the last Nyloc and insert the 10x55mm bolt through the arm of the

 

XTH350-01 bracket. Making sure the XTH350–01 bracket sits flat on the control arm, tighten the U-bolts and ¼ Flange nuts. Now tighten the 10mm Nylocs.

 

4.)Repeat these steps for the Right Front and Bag #2

 

NOTE: On the 2000-03 Rancher Honda ran the brake hose on the front leg of the control arm. On the 20004 and later the brake hose is on the rear leg of the control arm. On the 2000-03 models there is a ¼ inch Nyloc nut in the hardware bag for relocating the hose. You will have to take it loose and move it from the stock location to one of the legs of the rear ¼ inch u-bolt. Be sure to check and make sure there is no binding of the hose at full lock turn in both directions.

 

5.)Begin by loosening the lug nuts on the right rear tire. Raise the unit, using a suitable

lifting device or procedure, until the rear tire is off the ground. If using a floor jack

with stands, chock the front wheels to prevent the unit from rolling. If using jack

stands, make sure the stands are placed under the frame and not the body. Make sure

the unit is stable and secure.

 

6.)Assembly for Bag #3. Remove the lower shock mounting bolt and discard. Remove

the upper front housing flange bolt and discard. Check the diagram. Install the 10mm

lock washer on the 10x55mm bolt through the XTH350–06 bracket then the shock

mount. Install the XTH350-08 spacer and the other XTH350–06 bracket. The

XTH350-04 can then be installed using the 10x30mm bolt, tightened finger tight.

Insert the 10x60mm bolt through the XTH350-06, 10mm flat washer, shock, 10mm

flat washer and XTH350-06 bracket. Install the 10mm nyloc and tighten finger tight.

Tighten all bolts.

 

7.) A good “Anti-Seize” compound should be applied to the lug studs and the tire/wheel

combination of choice installed. Remove all jacks, jack stands and other devices used

to lift and hold the bike. Check all brackets and bolts to be sure everything is tight.

 

 

WARRANTY: This kit will be warranted against defects in workmanship and materials ONLY. Problems from misuse, improper installation or abuse are not covered in the warranty. This warranty is good for one year (12 months) form date of purchase. All warranty claims MUST be accompanied by the original receipt or suitable proof of purchase date.