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Rancho Gives You a Behind-the-Scenes Look at the New Rhino Lift Kit

Rhino before and after the 2007 Rancho Rhino Long-Travel Suspension System
Here at the Prototype Shop in Long Beach, Calif., Rancho Engineer Chris Batsch took the time to show us how to install the 2007 Rancho Rhino Long-Travel Suspension System.

The Rancho Rhino system features billet 6061 aluminum upper control 4-in. A-arms with contrast machining, HSLA steel lower control arms, exclusive self-lubricating control arm bushings, and high-strength tie rod ends and inner tie rod. This system is available for 2004-07 Yamaha Rhino models (p/n RS10001) and 2008-09 Yamaha Rhino models (p/n RS10011).

Let’s see how it is done:

Begin Installation

Removing the caliper, wheel hub and steering knuckle

To start the installation on the 2007 Rhino, begin by removing the caliper, wheel hub and steering knuckle. Be sure to wear eye protection during this installation!

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Removing coil-over shock, then upper and lower control arms

Remove coil-over shock, then upper and lower control arms.

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Removing the front axle and CV joint assembly

Remove the front axle and CV joint assembly. Now you’re ready to replace the axle shaft.

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Removing the boot clamps, circlip, inner CV and outer CV

A. Remove boot clamps.
B. Remove circlip.
C. Remove inner CV.
D. Remove outer CV.

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Transfer the reference marks to new axle shaft

Now, transfer the reference marks to new axle shaft. Rancho has increased the length of the axle shaft to accommodate the system’s long-travel design.

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Installing components on new axle shaft

Install components on new axle shaft.

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Loosening and removing the outer tie rod

Loosen and remove outer tie rod.

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Unthreading the inner tie rod and removing it from the steering assembly

Unthread inner tie rod and remove from steering assembly.

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Installing new inner tie rod making sure to not overtighten

Don’t forget to apply threadlock to new inner tie rod and install. Be sure not to overtighten!

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Rancho

Rancho’s suspension design includes highly engineered billet 6061 aluminum upper control arms with a contrast machined finish.

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Assembling the upper control arm

Assemble the upper control arm by attaching lower shock mount, male rod end and four bushings.

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Placing frame stiffener at front of frame rails and attaching front and rear mount of upper control arm to the frame brackets

Place frame stiffener at front of frame rails and attach front and rear mount of upper control arm to the frame brackets.

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Repeating the process with the lower control arm

Repeat the process with the lower control arm.

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Re-installing steering knuckle on outer CV shaft

Re-install steering knuckle on outer CV shaft and attach Rancho’s precision high-strength rod ends with the high-misalignment sleeves.

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Re-installing brake shield, rotor and CV shaft nut

Re-install brake shield, rotor and CV shaft nut.

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Installing adapter assembly on front shock absorber. Placing coil spring over shock absorber and installing spring retainer.

A. Install adapter assembly on front shock absorber.
B. Place coil spring over shock absorber and install spring retainer.

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Installing front shock absorber assembly and adjusting spring height

Install front shock absorber assembly and adjust spring height with the supplied spanner wrench.

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Attaching reservoirs on front frame and installing the wheel

Attach reservoirs on front frame using the supplied clamps and self-tapping screws, then install the wheel. Repeat a similar process for the rear suspension.

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