Today we’re going to wake up the blue horned creature so that it has the ability to sprint among the fastest of the crash(pack of Rhinos) just like it was meant to. We’re also going to spruce up the stock seats with some great looking seat covers that really set off the blue and silver colors on our special edition. So sit down, buckle up and grab on tight…because we’re going to make this Rhino charge!

Run Forrest…

We’re going to start off with a simple CDI upgrade, this small box will not only give you a higher rev limit, but it will also allow your Rhino that peppier feel off the line. The CDI is located in the battery box under the hood, simply lift up the battery lid, remove the bolt and nut securing the box, and then switch the rev limiters; and that’s it, you’re ready to go.

Grizzly power…

This next upgrade is going to take a little more time and effort, but in the long run you’ll be glad you did it. Replacing the Rhino clutch sheave with the Grizzly sheave will increase the top end speed, and lower your current RPM’s. For this job you can contact your local Yamaha dealer for the parts on the sheave replacement. The part numbers are as follows:

Sheave: 5KM-17620-00-00

Seals: 93101-35001-00 (quantity of 2)

Now that we’ve got all the parts needed for the job, let’s remove the driver’s seat and cowling so that we can begin to get our hands dirty.

The cover you will need to remove is located on the drivers’ side of the motor.

• Remove all of the bolts that secure the cover to the housing, and make note of any that are different in length so that you can return the right bolts to the proper holes during re-assembly. While removing the cover bolts, also remove the bracket bolt that secures the aluminum coolant line to the frame just below the cover.
• When all of the cover bolts are removed you will need to maneuver the coolant line out of the way so that the cover can be completely removed from the motor area.

• Remove the (4) bolts that secure the housing surrounding the clutch assembly. Be sure to mark the location of each of the bolts, and also mark the top of the housing for easy re-assembly.

• Next, insert (2) metric bolts in the holes near the center shaft of the fixed pulley (tighten gently). This action will relieve tension on the belt for easy removal/install of sheave.

• Before continuing, take a permanent marker and mark the sheave shaft and the sheave itself so that it can be assembled in the same manner as it was from the factory.
• With the use of an impact, remove the 22mm nut and washer on the Sheave (right side). Once the nut and washer are off, grab the sheave assembly and gently pull it off of the shaft.

• Remove the eight Phillips screws holding the cover plate on the sheave.
• From this point, everything from the old sheave will need to be installed into the new Grizzly sheave (with the exception of the 2 new shaft seals that will replace the existing ones. Be sure to use quality grease on the new sheave assembly as you transfer the existing internal parts. Also be sure to locate the same area on the new sheave to mark for your shaft location for re-assembly.

• Once the new sheave is properly assembled and ready, push in the center area just inside the cover until it stops. This action will reduce the chances of the internal weights moving from their designated spots during re-assembly. If these weights do move during assembly, you will need to open up the sheave again and return the weights to their proper locations.

• When replacing the sheave on the shaft make sure that the shaft splines properly align with the clutch assembly. You may need to maneuver the belt around during the replacement of the sheave for proper shaft insertion.

• Once sheave has been properly installed, re-install the washer and nut while moving belt to insure it isn’t binding.

• Install the clutch housing using the four bolts set aside, and then remove the two metric bolts from the center of the left pulley. Give the sheave a couple of spins with your hand to retain belt tension.

• Remove all tools and supplies from the area; place the vehicle in neutral with the parking brake on. Start the motor and check for proper operation. If everything looks good shut off the motor and re-assemble!

With this modification you will experience a much higher top end speed than previously experienced in your ride. You won’t be disappointed!

Comfortably eye catching…

Now that we’ve got a fast ride…let’s make it look the part! Installation of the new padded seat covers was quick and easy, just a couple of minutes per seat and as you can see, our special edition Rhino looks better than ever! Palo Verde Powersports provides wonderful workmanship, great designs, and a large array of colors and fabrics to choose from when it comes to Rhino seating. VP has been supplying seat covers to the ATV and Dirt Bike industry for the past five years, so moving into the UTV market seemed the next logical step. With over 1,000 patterns in stock for seating alone, VP is ready for your off-road seating challenges. For those of you looking for something special on your ride, VP can inlay laminated full color graphics into the seating…the skies the limit!

I would like to thank Verde Powersports for their contribution and support of this Rhino Project.

If you have any questions, feedback, or suggestions for his project please e-mail us at: bluehorn@off-road.com we look forward to hearing from you, until next month…

As always, ride hard, tread lightly, and travel often…

Mike Martin

Verde Powersports:
www.verdepowersports.com

Rhino seat covers