05-Up Honda Rincon

Kit No. XTH680

 

 

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 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, XTH655-01, 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 XTH655 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 XTH655-01bracket. 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

 

NOTE: Disconnect the rear sway bar at this time. DISCONNECT THE LINK / CONTROL ARM CONNECTION ONLY! on each side. Push the sway bar up and out of the way. This will be reconnected last.

 

6.)You should not need to remove the tires to install the rear parts. You will need a

suitable lifting device or procedure, to lift and lower the rear of the bike. If using a

floor jack, chock the front wheels to prevent the unit from rolling.

 

7.)Remove the four Torx head screws and two hex head bolts that hold the rear center

plastic panel. Removing this panel will give you access to remove the muffler.

Loosen the clamp bolt at the left rear wheel opening. There are two bolts above the

muffler, remove these and you can remove the muffler. It helps to spray the tailpipe

and muffler where they are clamped together. After spraying this area with a lubricant

like WD-40 or similar, you can begin to rotate the muffler up and down to break the

connection and slip the muffler off the tailpipe.

 

NOTE: When reinstalling the muffler be sure that the metal sleeves are still in the rubber mounts. There are rubber mounts, using a steel sleeve to prevent crushing, that the muffler is mounted with. Failure to reattach the muffler in this manner can lead to some broken parts later on.

 

 

 

 

 

8.)With access to the upper shock bolts you can now remove these bolts. Removing

these bolts may require raising and lowering the bike to take the load off the bolts.

Once the bolts are out raise the bike until the shocks are completely out of the

crossmember. There is a wiring harness that is attached to front side of the

crossmember. Reach inside the crossmember and you will feel the tab on the

mounting clamp pinch the tab’s tangs together and push the tab out of the

crossmember. Do this on both sides.

 

 

9.)Take one of the bolts furnished and slide it through the large end of the –02 bracket

(these are the small ones, there should be two) install this bolt from the rear into the

factory shock holes. Make sure the other end of the bracket is pointing to the outside

of the bike. When installing this bolt be sure to insert one of the spacers furnished.

Insert the outside bolt and repeat these steps on the other side.

 

10.)You should have four bolts protruding from the crossmember. Take the –01 (the

large one) and install it on the four bolts. Install a flange nut on both of the inner bolts

(the two bolts in the factory mounting positions) and only start them at this point.

 

 

 

11.)Remove the bolt in the new outer position. Move the top of the shock to the new

outer position and starting the bolt from the rear insert it through the bracket and the

shock eye. You may have to raise or lower the bike to get the bolt aligned with the

-01 bracket. Once you have both sides attached tighten all four bolts.

 

12.)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. The sway bar must be parallel

to the ground. If the drawing is not clear enough go to

www.xpatv.com/hondaswaybar.htm

and you will find more pictures as how the bar should be 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