Yamaha Kodiak/Big Bear 4x4

1997-1999 Kodiak & 2000-2006 Big Bear

Kit No. XTY400

 

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

 

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. Remove the lower shock-attaching bolt. Slide one of the small link brackets on a 10x55mm bolt. Insert the spacer into the stock shock mount, insert the 10x55mm bolt through mount and spacer. Install the other link bracket and tighten the nut finger tight. Do not tighten. Take the other 10x55mm bolt and insert it into the link bracket installing the 10mm washer between the link bracket and the shock. Tighten finger tight. Install the shock brace on the bolt and start one of the flange nuts. Next install the u-bolts from the bottom up into the shock brace and install the ¼ inch flange nuts. Making sure the shock brace sits flat on the control arm, tighten the U-bolts and ¼ Flange nuts. Now tighten the 10mm flange nuts.

 

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

 

 

 

Rear

5.)Begin raise the unit, using a suitable lifting device or procedure, until the rear of the bike 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 it is stable and secure you will need to be able to lower the rear axle without the rest of the bike moving.

 

6.)Assembly of Bag #3. Remove the lower shock mounting clevis pin and discard. On some models this can be tricky. We recommend that you spay the pin and let it sit for a few minutes. Remove the housing flange bolts and lay to one side. You can tell which bolts to remove by taking the large shock brace bracket and using this as a template remove bolts indicated. Install the 12mm 12x70mm (the shorter one) through a link bracket then the housing shock tab. Next insert the spacer included pushing the bolt through the sleeve, the other link bracket then the other housing shock tab.

Hold one of the 12mm flange nuts in place as you push through the left hand housing shock tab. Failure to do this at this time will cause you to have to disassemble some of the procedure.

 

7.)Next take the longer 12mm bolt and insert it through the link bracket, shock, other link bracket and finally the shock brace. Install the 12mm flange nut. Tighten all hardware at this time.

 

 

8.) 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.