RZR Long Travel install

I ordered a Super ATV Billet Aluminum 6" Lift & +6 Long Travel kit. HRR got me sweet deal, thanks again James. I had planned on going with a steel kit but happened to catch the billet kit on sale at a ridiculously low price so it was too good to pass on. I ordered the kit with complete Rhino axles. All the A-Arms, brackets, and adjuster links are polished. Kit uses HD heim joints on all the a-arms insted of businings. The lift brackets are HD and well made.

Problem is now it's going to be too purdy to get muddy...NOT



Figured I'd do a step by step install with pictures for those are interested. I will add comments on ease of installation, pros/cons of the kit, and quality of the parts.



Step #1 - Lay out the boxes and check for UPS damage.







Step 2: Open all the boxes and drool while having a beer







To be continued...

Nice...keep us posted....that is on my wish list

Sip beer , drool , check Visa account , Cry , Drink Beer and wait for you to get started .

Hey what shocks are you gonna use?

bcfatvs wrote:

Hey what shocks are you gonna use?

LTR450s on the front and YZ125s on the rear.

Those can be used on the stock A-arms, correct?

bcfatvs wrote:

Those can be used on the stock A-arms, correct?

Correct

Step 3 : Remove front suspension. I removed the front bumper and facia to allow easy access to all the components. The a-arms, axles, shocks, and tie rods removed and will not be reused. The stock spindles will be modified and reused as will the rack boots.











Closeup of the rack with the tie rods removed.





I also removed the front diff for service. The AWD was coming in later than it should. The rear tires had to spin several revolutions before the front would engage. I think the armeture plate is bent slightly causing the problem. Already have a new one ready to install. Will check everything in the diff when I install the new plate.

great post and pics!

Got the new armature installed in the diff after a slight delay. I'm usually very carefull but somehow I managed to strip two of the allen head bolts holding the diff cover on Had to drill and easy out the bolts and run to Lowes for some temporary bolts. Hard to find a countersunk 6-1.0 x 25mm bolt on a Saturday So I'll replace those later. Anyway got the diff put back together and re-installed.



Finally got to actually install some of the kit.

Step 4: Install A-arms











Step 5: Install axles and spindles.









Step 6: Install top shock bracket. It bolts in-pace where the stock shocks where and spans from one side to the other. Will make for a solid shock mount and prevent flex. Got the bracket installed, sorry forgot the picture (later).



Step 7: Install shocks. This is where I figured there might be an issue. The LTR shocks are longer than stock and will not line up without modifying the brackets. Good news it will allow me to lay the shocks to the most inward setting for a soft ride and still maintain maximum lift. I need to grind the top shock bracket for shock clearance. Will also have to modify the bottom bracket where it bolts to the a-arm. The bottom brackets are seperate from the a-arm and are adjustable for position. Should not be too difficult to fab something up. However, that's enough for today, the old back and knees ain't what they use to be.



My garage helpers:

RZR_Joe



Looking good but what is the aux cooler for if you dont mind me asking?

Firepup wrote:

RZR_Joe



Looking good but what is the aux cooler for if you dont mind me asking?

Oil cooler

I luv the dog. He's great. Once again, Very good post. I'm looking into doing the same thing to mine sometime this winter. Just can't decide on the shock package.

bcfatvs wrote:

I luv the dog. He's great. Once again, Very good post. I'm looking into doing the same thing to mine sometime this winter. Just can't decide on the shock package.

Light brown is Lucy and the dark brown is Daisy, otherwide known as peanut butter & chocolate. Both moma's little girls, they are sisters but could not be more different.



Shocks, so far I have really liked the LTR & YZ combination. They work well and for fraction of the cost of others.

That looks like a very nice kit. I like the looks of the heim joint setup. Can't wait to hear how they hold up compared to the stock crappy bushing setup.

Looks great so far ---

nice seen one at windrock that a guy had done and he rode with us and he loved his that is a sharp set up

Did not get much done today but I did manage to get teh front shocks worked out. Notch the top shock tower and relocated the lower shock bracket further out on the a-arm.















Ran in a snag with the tie-rods. The end that attaches to the hub has a threaded rod where there should be a rod end. I'll give them a call in the morning and get them to send the right part. It actually was a good stopping point anyway, it's lazy rainy Sunday here LOL.

Cant wait to see it when finished!!

Ok, That makes since... thats a good idea. Thanks for the info.

RZR_Joe wrote:

Firepup wrote:

RZR_Joe



Looking good but what is the aux cooler for if you dont mind me asking?

Oil cooler

rzr_joe, im impressed. i could never install a kit like that. if i was going to post how i got a kit installed i'd have to post a cancelled check to the dealer. lol. great work bud.

punder wrote:

Sip beer , drool , check Visa account , Cry , Drink Beer and wait for you to get started .

more pics rzr joe

way to go Rzr Joe....

Talked to Super ATV about the tie-rods issue. They are expressing out the heim joints. So far I've had nothing but excellent customer service from thode guys.



Got home too late to do much tonight so I'll give some comments on the kit so far.



1) Billet A-Arms - truely a work of art! They well designed, very beefy, and polished to a mirror finish.



2) Heim joints - Heavy duty 3/4" plated carbon steel on all arms. These will require cleaning and lubing after each ride in order to maintain good working order. We clean the vehicles throughlt after each ride anyway so no big deal for me.



3) Lift brackets - 1/4" steel heavy duty & powder coated. The front shock tower bracket is made from two plates with tabs welded between them. The rear is two seperate pieces. I had Rubberdown Customs 3" and the bracket were not nearly as heavy duting as these.



4) Overall design - so far it seems very well thought out. However, the trail will tell the tale.



4) General parts quality - Bushings, spacers, welds, etc...Excellent. Would have liked to see grade 8 hardware insted of grade 5. I'm sure grade 5 is adequate to meet the stresses any of the parts will ever see. However, I believe in over engineering hardware so they never become an issue.



5) Instructions: Poor at best. So far this is the only thing I can complain about. The kit comes with all the parts bagged and labeled. The instructions do not refer to the parts by part number. They instructions do not reflect changes to the kit as the design has been refined. Being a bit mechanical inclined it's not big deal but I could where they would confuse some.



Overall: Excellent, truely good to see a company deliver a good product at a reasonable price. Hard to find that these days. I would rate the kit a 9 out of 10. If the instructions were better and used grade 8 it would be a 10.



However, the true test is yet to be seen - How it performs ont he trail.

I see the grade 5 as a break point , with grade 8 you would bend parts .... Just a different view .