KIT NUMBER 8051510 YAMAHA RHINO Electric Steering Installation Manual Thank you for purchasing our ELECTRA-STEER 12v electric assist power steering system. Please carefully read this instruction sheet entirely before you begin to install the system. Remember before beginning installation, to insure that you are in a well lit, organized work area. Engage the parking brake, disconnect the battery until power is needed and chock or block the rear wheels to insure the vehicle is stable.
INSTALLATION TIPS: Due to minor variations in vehicle frames, we recommend 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.
Installation Instructions for YAMAHA RHINO 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.
. 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. NOTE: PINK COLOR BANDS FACE VEHICLE SPLINES AND WHITE FACE MOTOR SPLINES.
. Your electric motor & module has come to you assembled. Install the bracket, module, & 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. Once you have the joint in place install the supplied pinch bolt through the joint and finger tighten.
. 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.
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 installed 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 frame & tighten to 15 ft. lbs. 11. Locate a spot on your dash and drill a ½ “ hole where you would like your LED to be. Be sure to leave enough wire to get to the LED light.
12. Tighten the u-joint bolts to 20 ft.lbs. 13. Your kit has been shipped with a rubber splash shield. This shield sits over the motor & module assembly. Fit the shield in place as shown and drill ¼ “ holes in the perforated areas of the shield through the plastic on firewall & framework. Install the supplied trim tabs to hold shield in place.
WIRING YOUR ELECTRA-STEER KIT: 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.
Yahama Rhino Supplement For Early Model Year 1. Remove original steering shaft after positioning 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.
In some cases the purple wire maybe substituted for a brown wire!! The Electra-Steer Power Steering Assist Unit is intended to be used in accordance with all safety recommendations of the original manufacturer of the vehicle as specified in the Owners Manual. This product is intended for normal operation of the vehicle as specified by the original manufacturer. Maval Manufacturing Inc.
4. Once you know what the codes are you can use this chart to tell where or what the problem may be. 5. Once you have determined what the problem is and make the necessary repairs, you can proceed to clear the codes by running a jumper wire from the white wire with the single spade connector on it to ground. 6. Verify the ignition is off. Place the white wire to ground. Turn key on, wait 5 seconds and the light should go out. When the light goes out turn off ignition and remove jumper wire.
