Yamaha Rhino Stretch Kit Beaver Pro PDF Owner’s Manual

The Beaver Pro cabs and accessories are in no way affiliated with the Yamaha Motor Corporation. Any use of the Yamaha name is only to identify their utility vehicle as it pertains to our accessories. Yamaha and Rhino are registered trademarks of the Yamaha Motor Corporation. Your BeaverPro™ Yamaha Rhino Stretch Kit should contain the parts listed below. Separate all parts from packing materials. Do not discard packing material until assembly is complete. Item quantities are listed in parenthesis below.

• Welded Frame Assembly (x1) • Roll Bar Extension (x2) • Driveshaft Cover (x1) • Rear Driver Floor Mat (x1) • Rear Pass. Floor Mat (x1) • Shifter Bracket (x1) • Extended Throttle Cable (x1) • Extended Brake Line (x1) • Transmission Coolant Line (x2) • Engine Coolant Line (x2) • Extended Drive Shaft (x1) • Extended Shift Lever Rod (x1) • Seat Belt Set (x2) • ½” Washer (x6) • ½”-13 x 1 ½” Long Bolt (x4) • ½”-13 Lock Nuts (x4) • ¼”-20 x ½” Long Screw (x21) • 3/16” Rivet (x24) • 1½” x 5/8” Spacer (x2) • 1 ½” Hose Clamp (x4) • 5/8” Hose Clamp (x4) • #10-13 Self Tapping Screws (x20) • Wire Spools (x6) • Crimp Connectors (x100) • Roll Electrical Tape (x2) • Hook Up Wire 18 Gauge Brown (1 Roll) • Hook Up Wire 18 Gauge Red (1 Roll) • Hook Up Wire 18 Gauge Black (1 Roll) • Hook Up Wire 18 Gauge Blue (1 Roll) • Hook Up Wire 18 Gauge Yellow (1 Roll) • Hook Up Wire 18 Gauge Green (1 Roll) • Hook Up Wire 18 Gauge White (1 Roll) • 4 Gauge Starter wire (2 x 3ft) • 4 Gauge Butt Connectors (x4) • Air Breather Extension (3ft) with 2 clamps (2008 only)

TOOLS REQUIRED FOR ASSEMBLY Ensure that you have the following tools available before you begin the assembly of your BeaverPro™ Yamaha Rhino cab kit. Note: Assembly requires two people. Electric Welder Crimp Tool Reciprocating Saw With Metal (2x) 3/4” Wrench or Socket Blade or Hacksaw 7/16” Wrench Angle Grinder Electric drill Paint Spray Gun or Can of Black 5/32” drill bit Spray Paint Utility knife Wire Cutters Rubber Mallet Wire Strippers

INSTALLATION INSTRUCTIONS For the steps involving dismantling or assembling OEM parts on your Rhino, please refer to service manual for full instructions. Note: Save all hardware for re-assembly. 1. Disconnect battery 2. Remove both seats 3. Remove engine cover 4. Remove shift lever and shift link rod 5. Remove plastic covers in front of seat brackets 6. Remove plastic floor (Do not cut until later step) 7. Remove driveshaft 8. Drain transmission and engine coolant 9. Remove transmission cooling lines 10. Remove engine cooling lines 11. Remove throttle cable 12. Drain brake fluid 13. Remove rear brake line 14. Cut Factory Harness a) Unwrap the electrical tape on the factory harness running above the floor pan of the UTV. b) Label each end of the separate wire bundles with marking tape and a marker. Cut between pieces of masking tape. c) Repeat previous instruction until all circuits have been cut.

15. Cut Roll Bar and Frame Note: To prevent injury, support the underside of frame on either side of cut with jack stands or other appropriate support. a) Cut the lower frame and metal floor pan in the location shown at right. The cut is 1” from the inside of the round cross member at the front of the UTV. Cut upper frame in the straight section of the top of the roll bar. Ensure that all cuts are square to roll bar and frame tubing. b) Cut airbox tube above floor pan leaving a minimum 3” straight section of tube on either side of cut. c) Separate both parts of ATV so that you have a gap of about 40” between the two parts. d) Drill three ¼” holes on end of cut roll bar tubes as shown on right. These holes are used to hole weld assembly in next step.

16. Install Frame Assembly a) Install the provided frame assembly and roll bar extenders between both ATV halves. Support, brace and jig so that all frame and roll bar tubes are aligned and square. NOTE: This is the most critical assembly step of the entire installation. Any misalignment here can result in handling and steering problems later. Carefully check alignment before continuing to step 17. b) Hole weld frame assembly in holes drilled in frame in step 15c. c) Recheck alignment and square of all tubes. d) If a misalignment needs to be corrected, re-drill holes and reposition frame in step 16a. 17. Fillet weld 4 cut roll bars on either end. 18. Fillet weld 2 cut frame rectangular tubes on either end. 19. Stitch weld new floor pan to existing floor pan. 20. Grind all welds if cosmetic appearance is required. 21. Paint all welds using textured black paint. 22. Extend factory harness. a. Extend each wire of the factory harness with a 32” piece of wire (provided) and two butt connectors (also provided). b. Repeat previous step until all circuits have been extended by 32”. c. When all wires have been extended, rewrap the harness with the electrical tape provided. Note: Use 4 gauge wire and connectors provided to extend the two conductors coming on the battery. 23. Install transmission cooling lines using provided 3/8” ID hose and 5/8” hose clamps.

24. Install engine cooling lines using provided 7/8”ID hose and 1 ½” hose clamps. 25. Fill and bleed cooling system. 26. Install extended brake line. 27. Fill and bleed hydraulic brake system. 28. Install extended throttle cable and adjust per instructions in factory service manual. 29. Install new shift lever bracket with ¼-20 screws provided (x3). 30. Reinstall shift lever. 31. Install extended shifting rod. Adjust per instructions in factory service manual. 32. Reconnect the battery. 33. Start ATV, check for leaks, operation of throttle cable and electrical system, tighten clamps and fittings and correct leaks and electrical problems as required. 34. Measure and cut plastic floor pan previously removed from ATV so that it fits snugly against the front of the frame extension. 35. Install cut plastic floor pan using either rivets or self-tapping screws provided. 36. Install new rear driver and passenger side floor pan using ¼”-20 screws and 3/16” rivets provided. 37. Reinstall plastic covers under the rear seats.

Download Yamaha Rhino Stretch Kit Beaver Pro PDF Owner’s Manual