Yamaha Rhino Power Steering Installation Instructions

INSTALAION TIPS:

Due to minor variations in vehicle frames, we recomend that you leave all the U-Joint pinch bolts loose until the motor is mounted. Then rock the steering wheel back and forth to allow the U-Joints to align themselves. Complete the installation by tightening these bolts.


Tools needed to complete installation:

• 3/8"Electric Drill
• 3/8" Drill Bit
• 1/2" Drill Bit
• Soldering Iron & Solder
• Open End Wrenches: 3/8", 8mm, 10mm, 12mm, 13mm & 17mm
• 3/8" Drive Socket Wrench and 6" extension
• Sockets: 15/16", 3/8", 8mm, 10mm, 13mm & 17mm
• Wire Stripper/Cutters
• Hammer
• 50 Ft Lb Adjustable Torque Wrench
• Scribe or Marking Tool
• Heat Gun

Yamaha Rhino Power Steering Installation Instructions

1. Before starting your installation, center your steering wheel and make sure your wheels are in line and straight.

2. Remove the pinch bolt that retains the u-joint to the steering shaft and the rack and pinion. Slide the shaft down towards the pinion and remove shaft from vehicle.


3. You will need to trim 1/8" of your stock steering shaft. Take a cut off wheel or similar tool and trim off the very tip of the shaft. This is to ensure there is no interference with the u-joint to shaft.



4. Remove the control module bolts from the frame and remove the module.





Note: The upper joint and lower shaft have been shipped attached and are in phase. The shaft, u-joint and motor are marked where the proper location is. You do not need to remove the upper joint, but you will need to remove the lower shaft for installation. Pay attention to the alignment marks and make sure you install them back into the same place.

5. Your electric motor and module has come to you assembled. Install the bracket, module and motor assembly over the stock bolt holes in the frame where the module was located. The upper joint needs to spline onto the stock steering shaft as you align mount bracket. One you have the joint in place install the supplied pinch bolt through the joint and finger tighten.





6. Install the stock bolts from the module to hold the bracket in place. You may have to leave out the bolt closest to the air box to allow pivot room to spline lower shaft to the motor. After shaft is installed center and tighten 6mm bracket bolts.



7. Once bracket and motor is mounted install the lower shaft and install the pinch bolts in the u-joints and finger tighten. Verify that the assembly is not binding. If it seems tight or binds you may need to loosen the 4 bolts on the column tube and adjust the angle slightly. This is usually not necessary.


8. Once you have confirmed that all is well you will need to drill the 2 extra holes in the frame using the two 3/8" holes in the mtg. bracket as a pilot.



9. When the holes are drilled you can install the supplied bolts through the holes of the backer plate and install through the holes drilled into the frame. Install the washers and nuts and torque to 20 ft lbs.



10. Remove the stock 6mm bolts intalled in the mounting bracket. Install the module back into its stock location and install the supplied 6mm longer bolts through the module and bracket into the frame and tighten to 15 ft pounds



11. Locate a spot on your dash and drill a 1/2" hole where you would like your LED to be. Be sure to leave enough wire to get the LED light.



12. Tighten the u-joint bolts to 20 ft pounds.

13. Your kit has been shipped with a rubber splash shield. This shield sits over the motor and module assembly. Fit the shield in place as shown and drill 1/4" holes in hte perforated areas of the shield through the plastic on firewall and framework. Install the supplied trim tabs to hold the shield in place.







Wiring your Yamaha Rhino Power Steering System

1. The heavy red wire needs to go to a constant positive 12 volts. We normally go to the battery but any constant source will work.

Note: The 30 amp slow blow fuse needs to be installed in line with this wire to prevent damage or fire. *Failure to do so may result in a short circuit or malfunction.

2. The heavy black wire needs to go to a constant ground. Again we prefer the battery but a good and clean ground is fine.

*It is strongly suggested that all connections made be soldered and tapped to insure integrity. Shrink tube is also supplied to seal your connections.

3. The white wire gets a single spade connector put on it and is used for diagnostic purposes, so it need to stay in an accessible spot.

4. The purple wire gets a single spade connector put on it and is used for diagnostic purposes and also needs to stay in an accessible spot.

Note: the White and Purple wires are used for trouble code reading and clearing. They need to be located in an accessible place. They do not get connected to anything.

5. The orange wire goes to one of the sides of the LED light.

6. The yellow wire is not used for this application. It may be trimmed back and taped into the harness.

7. The green wire is connected to a key on power source. Usually we use the ignition switch lead. The other side of the LED also goes to this wire and may be spliced in anywhere in this wire.

8. Be sure to leave the orange wire and the green wire long enough to go through a hole in the dash where you want the light located.

9. Make sure your connections are good and your hardware is tightened to spec and there is no binding in your steering linkage.

10. Install your steering wheel and torque to 35 ft pounds. Make sure your wheels are straight and that you install your steering wheel straight.

Yamaha Rhino Supplement for Early Model Year

1. Remove original steering shaft after positoning front wheels straight forward. Cut off the 1/8" bit from steering shaft assembly and proceed as follows

2. Place power steering unit on steering spline so four parallel holes in steering bracket line up horizontally on frame cross member, temporarily securing it with C clamps.

3. Install the new steering shaft to unit and to the Rhinos rack and pinion system. Leave the pinch bolts finger tight.

4. Rotate steering wheel and watch rotation of steering shaft u-joints. Raise or lower the mounting bracket until u-joints clear the brake light sensor and turns free of any other obstacles.

5. Double check your shaft clearance and tighten C clamps in place in your final position. Take a measurement from the square frame end wrhe the round tube is joined to it and measure to the center of the first 3/8" bolt it should be about 9-1/16"

6. Use a center punch and mark and rill the 2 3/8" holes through the frame crossmember using the bracket holes as a guide.

7. You will need to grind off the lower inside corner of the backing plate until it lines up with the holes you have drilled.

8. Install the 3/8" bolts through the crossmember and backing plate, with the backing plate on the rear side of the crossmember. The inside bolt will protrude through back side of backing plate near a flat section of cross frame brace. Using a dremel or other precision grinding tool, notch the flat metal cross frame support to allow the 3/8" nut to attach to inside bolt.

9. With unit installed and steering shaft in place, torque all pinch bolts to 20 ft pounds. Turn wheel both ways and double check for clearance and no binding. Proceed to wiring procedure.

The Electra-Steer unit is designed to "shut down" if it becomes overheated reverting the vehicles manual steering capabilities.

If the unit ceases operation after extensive use or in an extreme environment it will automatically resume it's normal function once it has cooled.