Kit No. XTH655

03-04 Honda Rincon

 

 

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.

 

Components:

The kit consists of two bags containing Hardware and Brackets.

Bag #1 for the Front

Bag #2 for the Rear

See the drawings included for help in component installation.

 

Disassembly / Installation Procedure

 

FRONT

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.

 

NOTE: In the next step you are instructed to insert the –01 bracket through the crossmember. On most models this is possible on some it is not. If you can not install the –01 bracket inside the crossmember it will fit on the backside. If you install it on the inside the –03 bracket will be installed on the outside of the crossmember in the front. If you have to install the –01 in rear on the outside the –03 will be installed inside the crossmember at the front. See Diagram included.

 

3.)Remove contents from Bag #1. This bag is for the front end. Looking at the assembly

sheet for bag #1 follow these instructions. Remove the upper shock attaching bolt.

Slide the long bracket, XTH650-01, through the factory cross-member from one side

to the other. Make sure that you have all wires and hoses pushed to each side and out

of the way preventing pinching. Slide one of the XTH4500-03 bracket on a 10x55mm

bolt. Install in factory shock mount, be sure to install the spacer so you will not crush

the factory mount. Insert the bolt through the new XTH650 bracket and install one of

the flange nuts. Next insert a 10x55mm through the other hole in the XTH4500-03

bracket then a 10mm washer on the bolt, insert the bolt through the shock eye. Install

another 10mm washer on the bolt then the other XTH650-01bracket. Install the 10mm

nyloc nut on the bolt. Do not tighten.

 

4.)Repeat these steps for the Right Front.

 

5.)Lower the vehicle and remove all the stands and jacks, you can now proceed to the rear.

 

 

 

REAR

6.)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.

 

NOTE: Disconnect both sides of the sway bar bracket by removing the nut from the pivot bolt attaching the link to the control arm. You will reinstall the links last.

 

7.)Assembly for Bag #2 should be followed carefully. Remove the upper shock

mounting bolts on both sides and discard the stock bolts. Insert a 10x55mm bolt

through the factory mounting bracket then the XTH655-02 bracket. Make sure as you

install the bracket that the offset on the shock attaching point of the bracket is so the

bracket will set to the outside of the shock eye. As you insert the bolt through the

factory bracket be sure to install one of the spacers. Next install the other XTH655-02

bracket. After inserting the bolt out the other side of the factory bracket install a flange

nut. Install the other 10x55mm bolt through the –02 bracket and the shock then

through the other –02 bracket. Install the other 10mm flange nut tighten finger tight.

 

8.)Repeat this procedure on the opposite side. Tighten all bolts.

 

9.)Lower the bike and remove all jacks and stands. Make sure all bolts are tight and

torque to specifications.

 

10.)Rear Sway bar links should be reinstalled at this time. Install the parts as shown in the drawing one side at a time. Leave the first side loose until you have both sides attached to the control arm and then tighten both sides.

 

See attached sheet for drawing.

 

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