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By: ATV Source
Turn Your ATV Into a Monster
Installing a Lift Kit on Our Yamaha Grizzly
660
ATV Source.com's Yamaha Grizzly 660 with
Gorilla's 5.5" Lift Kit. |
Utility ATVs today come stocked with ground
clearance numbers that are double, sometimes
even triple what they were just a few short
years ago. Even so, the demand for quality lift
kits remains strong because of the fact that
there is no shortage of pudding-like mud holes
in the world just waiting to swallow a quad up
to its frame. Like the 4x4 auto industry, lift
kits exist to increase ground clearance (average
of 2 inches) so that larger tires can be
installed. With a two-inch increase in clearance
with the stock tires reinstalled, it isn't
uncommon to achieve a total of four inches
gained with beefier aftermarket meats. Extreme
kits can offer numbers as impressive as a full
twelve-inch gain in clearance for those who want
to ride high on the horse--literally.
Aside from function, lift kits offer a
cosmetic advantage as well, turning any quad
into a miniaturized monster-truck. The benefits
of being higher off the ground become clear in
more conditions than just mud-crossings as well.
Rocks, roots, and rivers become much more
enjoyable with a few extra inches of travel to
work with.
While the market offers several types of ATV
lift kits, a majority of them exist for a
specific machine making shopping for a kit
easier than one might initially expect. The
first step is to research your ATV on the web
(or at your local dealer) to gather as much as
you can about the machine's stock suspension.
Once you understand your stock specs, it is time
to factor in the benefits of running simply a
lift kit while retaining the stock tires or
adding taller aftermarket rubber to the kit's
increase. To this end, sky isn't always the
limit. It is critical to balance the overall
handling traits of your particular ATV. If your
wheelbase feels compact and nimble in stock
trim, it may be wise to consider a minimal lift.
Remember that the higher the ATV is from the
ground, the higher too, does its center of
gravity become. This means plan on relearning
your quad's physics when turning so as to
compensate for the increased risk of
overturning.
We recently spent some time with Gorilla's
5.5-inch lift kit designed specifically for the
Yamaha Grizzly 660 (2002-2007). Gorilla
Suspension kits are made from the highest
quality materials and are designed to fit the
ATV as a completely bolt-on endeavor, in other
words no cutting or welding needed to perform
the install. Let's take a look at the process of
performing the installation.
Removal of the wheel hub.
Removal of old axle.
Installation of brackets D1-D4.
Installation of part E1-E2.
Only after all the parts are installed,
we snug things up. |
FRONT
The process begins by having you remove the
wheels and wheel hubs from the swing arms. The
upper swing arms themselves are then removed
with the shocks from frame. Next, off come the
tie-rod ends from stock tie-rod, which are
replaced with the supplied Heavy Duty Tie-rods.
Next, it's time to install bracket A1 through
frame and place outside of the front factory
swing arm mount. Before adding A2 to the
opposite side of factory frame mount with
bracket A1, you will need support spacers, which
are included in the kit. Two 2-inch spacers will
be placed between brackets A1-A2 and A3-A4. The
purpose of these spacers is to ensure alignment
for the brackets, so don't attempt to tighten
any bolts until the correct spacer is installed
correctly. Next, place the A2 bracket with the
same process as A1. Add spacers and place 3½
inch-long bolts through the brackets and
spacers. All of the bolts require two flat
washers and one nylon nut. Don't get over
anxious. Do not tighten any bolt until
installation of this lift is complete. The same
procedure is performed for A3 and A4 as you just
did for A1 and A2.
Now it becomes time to remove the lower swing
arms from the frame. Once complete, remove the
front axles from the differential. The kit
includes eight individual B1 brackets that will
be placed on the outer sides of each factory
swing arm mount along with four 1 7/8 inch long
spacer supports that will be placed inside each
swing arm mount. Install 3½ inch long bolts
through each of the brackets and spacers. Do not
tighten these bolts yet. Remove the skidpan from
frame and set aside. Now locate the two brackets
labeled B2. After locating these two brackets,
place under frame and between brackets B1. Align
holes and place 3 ½-inch long bolts through B1
and B2. Do not tighten bolts until swing arms
have been assembled to support brackets. Now
install lower swing arms with 3½ inch long bolts
and the two front Gorilla axles. Install upper
swing arms with 3½ inch-long bolts. Connect
wheel hubs to swing arms. Bolt the brake caliper
to wheel hub. Note: You will need to route the
brake line across the upper swing arm to
accommodate for the difference in distance
between wheel hub and frame. There will be two
electrical ties in your kit that you will use to
strap the brake line to the swing arm.
Next place bracket C1 inside the factory
shock mount on the frame with one of two support
spacers located in your support spacer bag that
are listed as front shock mount spacers. Bracket
C1 will actually lock itself inside the shock
mount to support the shock. Place bracket C2 on
the outside of factory shock mount and use two
2½ inches-long bolts, one for the shock and one
for the shock mount. Do not tighten bolts until
the shock has been connected to brackets and
upper swing arm. Use the same procedure for the
opposite side.
REAR
Remove rear wheels and wheel hubs. Remove
upper swing arms and rear shocks. Locate
brackets D1 through D4 in your kit. You will
also need spacer support bags for the upper and
lower support brackets. One bag will have four
two inch-long spacers that will be placed in
between brackets D1-D2 and D3-D4. The other bag
will have eight 1 7/8 inch-long spacers that
will be placed in each of the upper and lower
swing arm mounts. Brackets D1 will be placed
through the frame and positioned on the outsides
of the swing arm mounts closest to motor. Place
D2 on opposite sides of the same swing arm
mounts using correct spacers and 3½ inch-long
bolts. Again, do not tighten bolts until
assembly is complete. Use the same procedure for
D3-D4.
Disconnect sway bar from rear lower swing
arms & remove swing arms from frame. Remove rear
stock axles. In your kit, locate the brackets
listed as E1. There will be eight brackets in
all and will be positioned on the outer sides of
the four factory swing arm mounts. Locate two
cross member brackets listed as E2. Place
brackets across bottom of frame and position
between brackets E1. Align holes and use 3½
inch-long bolts with four 1 7/8 inch-long
spacers to assemble the brackets. Place the rear
Gorilla axles into differential. Bolt upper and
lower rear swing arms to support brackets and
reconnect sway bar to lower swing arms.
Locate brackets F1 and F2 and the support
spacers for rear shock brackets. There will be
two 1 1/8 inch-long spacers that will be
positioned inside the shock mount located on the
frame. There will also be two 1 1/4 inch-long
spacers that will be positioned between brackets
F1 and F2. Position brackets F1 and F2 on the
outer sides of factory shock mounts located on
frame. Place spacers as described in instruction
A and use 2 ½ inch- long bolts to assemble. Do
not tighten bolts until the shocks have been
secured to the lower swing arms and brackets F1
and F2.
We had three minor issues with the
installation. Our first issue was the
plastic skid plates had to be completely removed
to allow the E2 brackets to fit in their
corresponding place. The second problem
was the use of the spacers between brackets D4.
With a support bar running across the frame, we
could not install the front spacers (see photo
for
support bar blockage). Our
third hiccup was the sway bar, which the
instructions said to re-install, but we later
found that we could not
re-install the due to a
wider wheel base. It is recommend to not
install the sway bar, as this will allow more
independent wheel travel.
That's it. The Yamaha Grizzly 660 just shot
up a solid 5.5 inches over stock and the total
time involved is just shy of two hours. The
Gorilla Yamaha Grizzly 5.5" Lift Kit includes
all of the materials for the job with
near-factory level fit and finish. Just how
satisfied are we with the finished product?
Well, let's just say mud hasn't been this
entertaining since that wrestling match broke
out in front of the sorority house. But, that's
another story entirely.
Before the 5.5" lift kit. |
After the 5.5" lift kit. |
For more information head to:
http://www.gorilla-axle.com/index.php?act=viewProd&productId=201
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