Yamaha Nytro Relocator Kit

Transcription

1 Included Parts: 1 Relocator bracket assembly 2 Upper assembly Oilite bushing halves 1 Lower steering block assembly 2 Lower assembly Oilite bushing halves 1 Tube of Loc-tite OFTRacing.com Scott Moto Yamaha Nytro Relocator Kit Step 1 Raise front of sled on jack stands until skis are just off the floor. Remove upper hood and side panels. Step 2 Remove 4 plastic instrument panel retainer rivets.

2 Step 3 Unplug ignition switch connector located near radiator cap. Step 4 Lay instrument panel off to left hand side of sled. It will hang from the display harness. (And 12V aux. power outlet harness if so equipped)

3 Step 5 Remove 4 plastic rivets from headlight stay. Leave the headlight stay where it is, this step is just to offer more flexibility during installation. Step 6 Remove two wire harness ties from steering gate, and pull harness down from hook on bearing retainer assembly.

4 Step 7 Bend tabs out of the way on the nut retainer. Remove 2 nuts that hold the bearing retainer bolts, and remove the bearing retainer assembly. Save these parts for reassembly.

5 Step 8 Bend tabs out of the way on the nut retainer on the lower steering bearing. Remove nuts from the studs; remove nut retainer and bearing retainer plate. Save these parts for reassembly. Step 9 Trim upper bearing retainer assembly with an appropriate tool to clear relocator bracket.

6 NOTE: Be certain to wipe ALL residual grease or goouck from steering shaft before installing new bushings. The new OFT Racing bushings may bind if there is any extra lube or filth on the shaft Step 10 Pull steering shaft upward/forward, and remove stock upper OEM bearing from steering gate and shaft. Install lower half of relocator bracket and Oilite bushing into steering gate using stock hardware. Finger tighten bearing retainer assembly nuts. NOTE: The oilite bushings for the relocator bracket are slightly longer than the bushings for the lower steering block, and should be marked as such. Use care to install proper bushings in each block.

7 Step 11 Remove lower OEM bearing and install new steering block bottom half and Oilite bushing. Bend mounting studs forward/downward gently until the block is flush with the sub-frame mounting tab. Install upper block half, bushing, bearing retainer plate, nut retainer, and nuts. Finger tighten.

8 We used a 10mm deep socket, and an extension to gently pry the studs forward/downward. Ensure lower half of steeing block is flush against sub-frame mounting tab. Step 12 Install upper relocator half and Oilite bushing using supplied Loc-tite and cap bolts. Wrench tighten relocator cap bolts and bearing retainer nuts (upper and lower). Bend nut retainer tabs over to nuts.

9

10 Step 13 Reinstall headlight stay using 4 OEM plastic rivets. Reposition wiring harness on hook of upper bearing retainer assembly, and reinstall 2 plastic zip ties onto steering gate. NOTE: The OFT Racing relocator moves the bars dramatically upward and forward. This movement will cause binding in the OEM throttle cable if it is left in the OEM routing position. To rectify this situation, it is imperative to reposition the throttle cable following the directions below. Failure to do so may cause your sled to act in an erratic manner with no prior warning. This may cause rider injury, property destruction or death.

11 The purpose of the following instructions is to reposition the throttle cable from above the handlebar riser to below the riser. Step 14 Remove right hand mountain strap bolt beside throttle block. Step 15 Remove throttle flipper pivot pin. Remove e-clip and washer from bottom of pin, (carefully, they re small and easy to lose) remove pin and upper washer.

12 Step 16 Remove 2 Phillips head screws from forward facing side of throttle block. Also, pull the grip warmer wire from the retaining slot in the throttle block.

13 Step 17 Split throttle block, and then pull apart as shown below. Step 18 Remove the 4 handlebar clamp bolts, handle bars, and extruded handlebar riser. Step 19 Hold handlebars and slide throttle block assembly over the end of the bars. Then, position throttle cable below steering riser. Ensure remaining throttle block wiring remains forward of handlebar riser.

14 Step 20 Reinstall handlebar riser, handle bars, bar clamps and bolts, and mountain strap. Torque to OEM specs. Step 21 Reinstall throttle block. (Reverse steps 15, 16 and 17) NOTE: Verify that all cable and wire routing looks like the next picture when you are finished:

15 Step 22 Remove rubber grommet from instrument panel. Trim panel as required to provide proper clearance for all wiring, lines, and cables. Reinstall instrument panel, then install grommet.

16 Step 23 Reconnect ignition switch harness plug. Step 24 NOTE: Installation of the relocator changes the geometry of steering components. It is necessary to adjust the steering relay rod to realign the handlebars with the skis. The steering relay rod is attached to the steering shaft at the bottom of the steering rod, and then runs down to the arm pivot assembly that is bolted into the sub-frame. Point skis straight forward. Loosen jamb nuts on steering relay rod. While holding skis straight, rotate relay rod until handlebars appear to be aligned with skis. Retorque relay jamb nuts to OEM specs.

17 Step 25 - Sweep handlebars from stop to stop. Ensure there is no binding of cables, hoses, wiring, or mechanical components. - Raise rear if sled until the track is 3-4 off of floor, and secure. - Start sled. - With sled idling, sweep handlebars from stop to stop. Ensure that engine RPM never surges or drops throughout the sweep - If there appears to be a change in RPM in the sweep test, readjust throttle cable tension as per service manual

18 Step 26 Reinstall side panels and upper hood. Lower rear of sled, and remove jack stands. Thank you for purchasing another innovative Over the Top part from OFT Racing!