APPLICATION The Timbersled Model No. J17RTAXXXA and J18RTAXXXA are designed specifically for the bike models listed below: • Yamaha ® — TTR110, 2008 to current • Honda ® — CRF110F, 2013 to current • Kawasaki ® — KLX110, 2003 to current; KLX110L, 2010 to current BEFORE YOU BEGIN Read these instructions and check to be sure all parts and tools are accounted for. Please retain these installation instructions for future reference and parts ordering information. KIT CONTENTS The ST90 Ripper Install Kit includes: Qty.- 1, Install kit for your specific model. ST 90 Ripper sold separately. REF QTY PART DESCRIPTION PART NUMBER 1* 1 Honda Install Kit 2882729 2* 1 Yamaha Install Kit 2882730 3* 1 Kawasaki Install Kit 2882731 4 1 ST 90 Ripper Install Kit instructions 9927988 Items marked (*) are specific to your make and model of bike. Only items specific to your make and model of bike are included in the Install Kit. See Install Kit drawings and parts lists for items specific to each Install Kit. Instr 9927988 Rev 02 2017-04 Page 1 of 12 P/N 9927988 ST 90 RIPPER INSTALL KIT
Transcript
APPLICATIONThe Timbersled Model No. J17RTAXXXA and J18RTAXXXA are designed specifically for the bike models listedbelow:• Yamaha®— TTR110, 2008 to current• Honda® —CRF110F, 2013 to current• Kawasaki® —KLX110, 2003 to current; KLX110L, 2010 to current
BEFORE YOU BEGINRead these instructions and check to be sure all parts and tools are accounted for. Please retain theseinstallation instructions for future reference and parts ordering information.
KIT CONTENTSThe ST90 Ripper Install Kit includes: Qty.- 1, Install kit for your specific model. ST 90 Ripper sold separately.
REF QTY PART DESCRIPTION PART NUMBER1* 1 Honda Install Kit 28827292* 1 Yamaha Install Kit 28827303* 1 Kawasaki Install Kit 28827314 1 ST 90 Ripper Install Kit instructions 9927988
Items marked (*) are specific to your make and model of bike. Only items specific to your make and model ofbike are included in the Install Kit. See Install Kit drawings and parts lists for items specific to each Install Kit.
Instr 9927988 Rev 02 2017-04 Page 1 of 12
P/N 9927988
ST 90 RIPPER INSTALL KIT
Instr 9927988 Rev 02 2017-04 Page 2 of 12
INSTALL KIT: 2882729This install kit is specific to the Honda models listed in the application section:
REF QTY PART DESCRIPTION PART NUMBER1 1 RDCR, Ripper - Honda, LH 5141218
IMPORTANTYour ST 90 RIPPER INSTALL KIT is exclusively designed for your vehicle. Please read the installationinstructions thoroughly before beginning. Installation is easier if the vehicle is clean and free of debris. For yoursafety, and to ensure a satisfactory installation, perform all installation steps correctly in the sequence shown.
ASSEMBLY TIME2–4 Hours
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INSTALLATION INSTRUCTIONSMOTORCYCLE DISASSEMBLY:
NOTEThe disassembly process listed is universal for allbikes using the ST 90 Ripper kit. This process mayvary slightly between makes and models. Refer to
your host bike’s owners manual for specificreferences and disassembly procedures.
1. Place bike on a stand or suitable support whereboth wheels are off the ground. Secure properly toprevent bike from tipping when wheels areremoved.(An adjustable stand is helpful forreassembly.)
2. Remove the seat and side panels.3. Remove chain by disconnecting master link.4. Remove the rear brake lever from frame and let
hang (this includes the spring).5. Remove upper rear shock bolt or pin.
NOTEKeep upper shock bolt for later use as this item will
be reinstalled.
6. Remove the rear swing arm bolt (this will drop theentire swing arm assembly off the bike) andremove the shock, tire, brake, and swing armassembly from the bike as a complete unit.
NOTEIt is recommended to cable tie all bushings, spacers,etc. to their corresponding parts at all pivoting points
to prevent losing any parts during storage.
7. Remove the front brake lever and cable retainerbolts from the bikes front forks. (On some modelsuse the provided cable tie to secure start button).
8. Loosen the front axle bolt and remove the frontwheel.
NOTEKeep front axle bolt for later use, this item will be
reinstalled.
9. Remove the front drive sprocket and sprocketcover.
10.Check to ensure all previous steps are complete.You are now ready to start the assembly portion ofthe process.
REAR RIPPER ASSEMBLYLeft Side Right side
SpacerSpec.
Part # SpacerSpec.
Part #
Honda 0.80mm
5141218 6.87mm
5141219
Kawasaki N/A N/A N/A N/A
Yamaha N/A N/A 15 mm 5141220
*Left and Right as positioned sitting on the bike
1. Locate rear track assemblyq and position it up tothe rear swing arm bolt location on the bike. Somefit kits will require spacerst on one or either sideof the frame, located between the Ripper framemount brackets and the bike’s swing-arm boltbracket location. See table at the beginning of thissection for specific bike model spacers.
NOTEKawasaki KLX models do not require any spacers.Honda CRF models require left and right swing armbolt spacers/reducers. Yamaha TTR models requirea single spacer positioned on the right side of the
bike.
2. Slide provided 7/16” x 6-1/2” swing arm boltr infrom the left hand side of the bike and tighten locknuty to listed torque specification.
TORQUE54 Nm (40 Ft. Lbs)
Instr 9927988 Rev 02 2017-04 Page 7 of 12
3. Bolt the lower portion of the strut rode to the kitassemblyq using the provided M 10 x 40mm boltw. DO NOT TIGHTEN until after upper portion ofstrut rod has been bolted in place.
4. See note below before continuing.
NOTEKAWASAKI MODELS ONLY skip Step 4 and
complete Steps 5 and 6. For Honda and Yamahamodels continue with Step 4.
Bolt upper portion of the strut rode into the bike’supper shock bracket using the bikes upper shockmount bolt or pin. For bikes using a bolt, torque tothe bike manufacturer’s specifications. Once youhave the upper portion of the strut rod in place,Torque the lower portion of the strut rod to thespecification listed below.
TORQUE61 Nm (45 Ft. Lbs)
For Honda and Yamaha models continue to theBrake Line Assembly and Routing section.
5. See note below before continuing.
NOTEThis step includes the upper strut rod installation and
brake line routing for Kawasaki models only.
Once you’ve completed Step 3 and before youfasten the upper strut rod bolt, move the strut rode up to provide enough clearance, feed the brakelineA and master cylinder over top of the rearright sub-frame tubingB of the bike and under thegas tankC as seen in the image below. Nowmove the top of the strut rode down back intoplace lining up the mounting holes.
NOTESome Kawasaki models can use secondary bolt hole
in the strut rod for lower ride height.
Bolt in place using the original upper strut rod boltor pin and torque to the bike’s manufacturer’sspecifications. Once you have the upper portion ofthe strut rod in place, Torque the lower portion ofthe strut rod to the specification listed below.
TORQUE61 Nm (45 Ft. Lbs)
6. Keeping all of the slack out of the brake line,fasten the brake line to the top and the bottom ofthe strut rod with provided cable ties in thelocationsF indicated in the image below.
WARNINGWhen routing brake lines it is critical that you keep allbrake lines away from any surfaces, such as engineor exhaust, that can become hot while operating thevehicle. Failure to comply will adversely affect the
vehicles brake system and may lead to severe injuryor death.
Instr 9927988 Rev 02 2017-04 Page 8 of 12
7. Run the brake lineA forward under the bottom ofthe gas tank along the main frame of the biketowards the bike’s front neck-tube. Make surethere is a minimum of one inch of clearancebetween the brake line and the lower head setturning stop postsB to prevent the brake line frombeing pinched. Place another cable tieF aroundthe brake line fastening it to the bike’s throttlecable keeper bracketC. The remaining brake linecan free hang up to the master cylinder mountedon the right handle bar. Adjust the pitch of thebrake lever, ensuring it is easily reached and easyto pull. Tighten the brake lever perch hand tightbeing careful to not strip the mounting perchthreads. If needed, you can loop any remainingslack in the brake line in between the right forktube upper and the neck-tube of the bike frame asseen in the photo below. (Honda model shown forreference)
WARNINGWhen routing brake lines, make sure there is a
minimum of one inch of clearance between the brakelineA and the lower head set turning stop postsBto prevent the brake line from being pinched. Failureto comply will adversely affect the vehicles brakesystem and may lead to severe injury or death.
For Kawasaki models, once you have completedStep 7 continue to the Drive Chain and SprocketAssembly section.
BRAKE LINE ASSEMBLY AND ROUTING
WARNINGWhen routing brake lines it is critical that you keep allbrake lines away from any surfaces, such as engineor exhaust, that can become hot while operating thevehicle. Failure to comply will adversely affect the
vehicles brake system and may lead to severe injuryor death.
• Yamaha ModelsNOTE
Refer to images of Honda model for routingreferences.
– For the Yamaha TTR models, run the brake lineforward either on top of the strut rod or locatedparallel against the left hand side of the strut rod.Secure the brake line to the strut rod with a cabletie located at the top of the strut rod and one at thebottom of the strut rod in a similar fashion to thephoto for the Honda model. From here feed thebrake line and master cylinder to the right side ofthe bike feeding the brake line between the bike’supper sub-frame column and the wiring harnessbrackets on the frame. This will help hold the brakeline against the bikes frame and as far away fromthe exhaust system as possible. From here routethe brake line forward towards the front of the bikeunderneath the bikes fuel tank. Place anothercable tie near the front of the bike securing thebrake line to the bikes lower horizontal frame tube.
WARNINGWhen routing brake lines, make sure there is a
minimum of one inch of clearance between the brakelineA and the lower head set turning stop postsBto prevent the brake line from being pinched. Failureto comply will adversely affect the vehicles brakesystem and may lead to severe injury or death.
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• Honda Models– Remove the two rear gas tank boltsA and loosen
the front tank bolt on the bike. Lift up on the rear ofthe gas tank giving yourself enough room to feedthe brake line and master cylinder over top of therear right sub-frame tubing of the bike and underthe gas tank as indicated in the image belowRFeed the brake line forward under the bottom ofthe gas tank along the main frame of the bike.Keeping all of the slack out of the brake line fastenthe brake line to the top and the bottom of the strutrod with cable ties as shownF. Reinstall the tworear gas tank boltsA previously removed andtorque to bike manufacturers specification. Next,torque the front tank bolt to manufacturersspecifications. See image below for brake linerouting referenceR:
– Near the front of the bike where the brake line isapproaching the front neck tube of the bike, cabletie the brake line to the front gas tank frame mountand another cable tie to the bikes frame-mountedwire harness on the bike’s neck tube. See photobelow for cable tie locationsF. The remainingbrake line can free hang up to the master cylindermounted on the right handle bar. Adjust the pitchof the brake lever, ensuring it is easily reached andeasy to pull. Tighten the brake lever perch handtight being careful to not strip the mounting perchthreads. See image below:
WARNINGWhen routing brake lines, make sure there is a
minimum of one inch of clearance between the brakelineA and the lower head set turning stop postsBto prevent the brake line from being pinched. Failureto comply will adversely affect the vehicles brakesystem and may lead to severe injury or death.
Instr 9927988 Rev 02 2017-04 Page 10 of 12
DRIVE CHAIN AND SPROCKET ASSEMBLY1. Install provided sprocketw and bearing carrier
housinge onto transmission output shaft. Makesure to use Blue Loctite® 243 on the provided 3button head screwsy. HONDA ONLY: Placeprovided spacerq onto output shaft beforeinstalling sprocket.
NOTEReference you host bikes owner’s manual ormanufacturers specifications for proper torque
specifications.
2. Tighten sprocket backer platee to the enginecase and torque to bike manufacturersspecifications before chainu is installed andchain tension is set.
3. Route chainu around both sprockets.4. Complete the assembly of the chain with the
master link provided. Be sure to install the masterlink with the opening of the link facing rearward inrelation to the chain direction.
5. Set the proper chain tension by loosening chainslider nut and bolt. Slide the chain slider up ordown until 1/2”-5/8” of vertical deflection is met inthe upper chord of the drive chain. Torque chainslider nut to specification below when propertension is achieved.
TORQUE25Nm (18 Ft. Lbs)
NOTEChain will stretch within the first 5hrs. You will wantto check for proper chain tension. Chain slider is notintended to roll and can be rotated as needed tokeep proper chain tension on usable surface of
slider.
FRONT SKI AND SPINDLE ASSEMBLYLeft Side Right side
RDCRSpec.
Part # RDCRSpec.
Part #
Honda 18.03mm
5141390 25.4mm
5141389
Kawasaki 17.35mm
5141392 17.35mm
5141392
Yamaha 14.91mm
5141394 20.49mm
5141393
*Left and Right as positioned sitting on the bike
1. Locate the front skiq, spindlee, ski rubberw,and provided hardware.
2. Place the Ski Rubberw on top of the center of theskiq with the indicated “Front” of the Ski Rubbertowards the front tip of the Ski.
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3. Place the lower portion of the Spindlee on top ofthe Ski Rubberw in the ski saddle to where theFork Clamp support bracket would be positionedbehind the front forks of the bike. Line up thebottom bolt hole and insert the M 10 x 155 mm boltr.
Apply nutt to bolt and torque to specificationlisted below.
TORQUE50Nm (37 Ft. Lbs)
WARNINGFailure to torque fasteners as directed will adverselyaffect the steering system and may lead to severe
injury or death.
4. Insert front spindle reducersy into spindlee.These will change per bike manufacturer. Yourindividual bike model fit kit will come with theappropriate spindle reducers/spacers, see thetable at beginning of this section for spindlereducer placement for your specific bike model.
5. Use existing front axle boltB to attach the frontspindlee to the forksA.
For now, just snug the front axle bolt, do nottighten until after step 6.
6. Using the composite fork clampa (fork clamphalves are identical), place one half of the forkclamp in front of the fork tubesA with the concaveportions sitting around the face of the lower forktube. Take the other half and mate it around theback side of the fork tubes between the fork tubesand the spindle backer plate. Take the Fork Clampwasher plates and place it over the face of thefront fork clamp lining up the bolt holes of thewasher plate with the clamp.
Using Qty.–2, M8 x 75mm boltsi supplied withyour kit, insert bolt through the washer plate, bothhalves of the fork clamp, and through the spindlebacker plate. Apply the supplied M8 locking nutso and torque to specification listed below.
TORQUE20Nm (15 Ft. Lbs)
Instr 9927988 Rev 02 2017-04 Page 12 of 12
7. Tighten front axle boltB.
IMPORTANTRefer to manufacturers specifications for proper
torque setting.
8. Check to ensure all previous steps are completethen move on to the rear cowling assemblysection.
REAR COWLING ASSEMBLY1. Install the rear cowlingq with the provided, Qty.–
4, nylon rivet fasteners.w.
2. Slide cowlingq forward under bikes rear fendermaking sure the front left chain guard portion ofthe cowling is positioned behind the DriveSprocket Plate.
3. Start with the front left side mounting holeA.Insert nylon rivet fastenerw. Repeat process forthe front right side mounting holeB, insertingnylon rivet fastener securely.
NOTEThe rear cowling is pliable, the easiest process forlining up the rear fastener mounting holes of the skidframe with the cowling holes is to pull out on the
bottom most part of the cowling in the middle of themolding. This will pull the rear hole in the cowling
forward allowing you to line up the holes to insert thenylon rivet fastener.
4. Repeat this process for both leftC then rightDrear mounting holes.
5. Check to ensure all tools are accounted for and allsteps have been completed in the proper order.
