Kit No. XTH500

02-04 Honda Rubicon 500

 

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 four bags containing Hardware and Brackets.

Bag #1 for the Left Front

Bag #2 for the Right Front

Bag #3 for the Left Rear

Bag #4 for the Right 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 shock braces on a 10x55mm bolt. Be sure

bolts install as per diagram. Next install a 10mm washer on the bolt, insert the bolt

through the shock eye. Install another 10mm washer on the bolt then the other

XTH4500-03 bracket. Install the 10mm Nyloc on the bolt. Do not tighten. Take the

other 10x55mm bolt and insert it into the –03 bracket insert the XTH3500-08 spacer

into the stock shock mount, slide the bolt through mount/spacer and through the other

–03 bracket. Install the 10mm Nyloc. Tighten finger tight. Remove the first Nyloc

and install the XTH4500-01 bracket on the 10x55mm bolt, tighten the Nyloc finger

tight. Making sure the –01 bracket sits flat on the control arm, install the U-bolts and

¼ flange nuts. Tighten the ¼ “ flange nuts first, then the 10mm Nylocs.

 

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

 

 

 

 

REAR DISASSEMBLY AND ASSEMBLY

 

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

lifting device or procedure, until the rear tires are 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 should be followed carefully. Remove the lower shock mount

and discard the stock bolt. Remove the top two 8mm flange bolts from the rear carrier

housing. Insert a 10x55mm bolt through the XTH5000-07 bracket then the XTH

4500-06.

sure of the indexing. Check the diagram. Install the Nyloc and tighten finger tight.

Install the 10x50mm bolt through the lock washer, XTH4500–05 bracket, stock mount,

the XTH4550-10 spacer, the 4500–06 bracket, into the shock mount and leave

loose. Next position the XTH5000–07 bracket and install the new 8x25mm bolts.

Tighten all bolts.

 

7.)Assembly for Bag #4. Remove the lower shock mounting bolt and discard. Remove

the upper rear housing flange bolt and discard. Check the diagram. Insert a 10x

55mm bolt through the 4500–05 bracket then the shock. Install a 10mm washer then

the 4500–06 bracket. The XTH5000-04 can then be installed and a 10mm Nyloc

tightened finger tight. Insert the 10x45mm bolt through the star washer, the –05, stock

mount, XTH4550-10 spacer, 4500-06 bracket and into the stock mount. Install the

10x25mm bolt through the housing flange and the XTH5000–04 bracket install the

10mm flange nut. Tighten all bolts.

 

 

 

 

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

combination of choice installed.

 

 

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.