Yamaha Kodiak

05-06

XTY455

 

 

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 plus bracket # 4055-01

Bag #2 for the Rear plus bracket # 4055-02

 

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.

 

NOTE: For ease of installation you may want to loosen the front rack and fender bolts to allow more room and easier access for the installation.

 

NOTE: Make sure shock adjusters are at their lowest setting. When reinstalling the shocks you may have to use a pry bar to compress the shock and coil depending on how new the bike is and the condition of the coil.

 

3.)Remove contents from Bag #1. Start with the front, on the passengers (right as you sit on the bike) side, remove the wheel and the top bolt holding the shock to the frame, loosen bottom bolt allowing you to pull the shock out and away from the upper mount. Repeat these steps on other side. Next slide the #4055-01 along rear inside of factory channel (x-member). Installing this will require some patience. Roll the long bar over on it’s side at a 45 degree angle and slide it all the way in. You may now set the bar up in the correct position. It will be snug. Place a sleeve in the x-member to help hold the bar in place. Using a 10x60mm bolt, going from rear to front, go thru the factory x-member, Xtreme bracket, sleeve and out the factory x-member. Start a flange nut on the bolt and proceed to the other side.

 

4.)The Left hand side will be the same as the Right side EXCEPT the bolt goes from Front to Rear. Placement of parts will be the same as before just the direction of the bolt will change. You may now readjust the shocks.

 

NOTE: Drawing #1 reflects above instructions

 

 

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, place jack under rear axle, you will need to be able to raise and lower the rear axle without the rest of the bike moving.

 

Assembly of Bag #2. It is not necessary for the wheels to be removed for the rear brackets but you may find it easier with the wheels removed.

 

NOTE: Take the two long rear brackets and look closely at them one of the inner holes is slightly elongated. (Slotted). There is also a relief built into the bracket to clear the belt drive ducting that is slightly off-center. The slots and relief both go on the left side looking at the bike from the rear.

 

6.)Lay both of the brackets on the drive ducting, making sure the brackets are phased properly. Take one of the 10x60mm bolts and insert it thru the bracket on the inner hole on one end. Hold the sleeve in place inside the factory mount. Go thru the sleeve and out the front of the factory bracket. (You may install these bolts front to rear or rear to front.) Install one of the 10mm flange nuts. Install the opposite side bolt, installing the sleeve as you did on the other side. Take another bolt and go thru the bracket and then install one of the thick washers. Go thru the shock install another washer and thru the other bracket. Repeat on the other side.

 

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.

 

 

ALL VIEWS ARE FROM LEFT SIDE

Diagram #1

 

Diagram #2

 

 

Diagram #3