Bulletin # PS-0308-8 March 2008
Yamaha Kodiak, Wolverine, Grizzly, & Rhino Piston Kits

New Product

Features Benefits Dedicated forging.. Light weight / Superior strength Stock Compresion.. Original characteristics Hi-Compression. Maximum torque and throttle response Dome design... Improved flame travel Chrome plated piston pin. Reduced friction / Scuff resistance Horizontal slot pin oiling.. Reduced friction / Scuff resistance Pressure seal groove.. Maximum ring seal Skirt coated... Reduced friction and quieter operation. Dedicated rings.. Maximum compression and oil control Experience.. 65 years as the industry leader in forged piston technology
Piston sold complete with: Rings, piston pins, and circlips. Prices (USA): Stock Compression: $154.36
Bore x Stroke (mm) 84.5 x 75
Bore Size (mm) 84.50 85.00 85.50

Top End Kit TBA

Top End Kit Piston Kit Number Price TBA 4939M08450 4939M08500 4939M08550

Price Per Piston $154.36

Repl. Ring Set 8450XX 8500XX 8550XX
Repl. Pin & Clips S520 CW20

Top End Gasket Kit TBA

Yamaha 450cc Kodiak Wolverine Grizzly Rhino Skirt coated

2006 2006-2006-07

Copyright 2008 Wiseco Piston Co., Inc. 7201 Industrial Park Blvd. Mentor, OH 44060-5396 440-951-6600 Fax: 440-951-6606 www.wiseco.

INSTALLATION INSTRUCTIONS
YAMAHA ATV WINCH MOUNTING KIT
Mount Kit: 63945 Application: YAMAHA KODIAK 03, 400 & 450
Your safety, and the safety of others, is very important. To help you make informed decisions about safety, we have provided installation and operating instructions and other information on labels and in this guide. This information alerts you to potential hazards that could hurt you or others. It is not possible to warn you about all potential hazards associated with this product, you must use your own good judgment. CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT. This guide identifies potential hazards and has important safety messages that help you and others avoid personal injury or death. WARNING and CAUTION are signal words that identify the level of hazard. These signal words mean: WARNING signals a hazard that could cause serious injury or death, if you do not follow recommendations. CAUTION signals a hazard that may cause minor to moderate injury, if you do not follow recommendations. This guide uses NOTICE to call attention to important mechanical information, and Note: to emphasize general information worthy of special attention.

WARNING

INJURY HAZARD Failure to observe these instructions could lead to severe injury or death.
Always use extreme caution when drilling on any vehicle. Make sure that all fuel lines, brake lines, electrical wires, and other objects are not punctured or damaged when / if drilling on the vehicle. Thoroughly inspect the area to be drilled (on both sides of material) prior to drilling, and relocate any objects that may be damaged. Failure to inspect the area to be drilled may result in vehicle damage, electrical shock, fire or personal injury. Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye injury. Always use extreme caution when cutting and trimming during fitting. Always remove jewelry and wear eye protection. Never lean over battery while making connections. Never route electrical cables: Across any sharp edges. Through or near moving parts. Near parts that become hot. Always insulate and protect all exposed wiring and electrical terminals. Always install terminal boots as directed in installation instructions. Always use appropriate and adequate care in lifting components into place. Always insure components will remain secure during installation and operation. Always tighten all nuts and bolts securely, per the installation and operation. Always perform regular inspections and maintenance on the winch, winch mount and related hardware. Never operate this WARN product with damaged or missing parts.

PARTS LIST:

PART NO. QUANTITY DESCRIPTION Winch Mounting Plate 5/16 Flat Washers -20 x 1.00 U-Bolts Flat Washers -20 Lock Nuts U-Bolt Spacer Plates Tab Extension Plate M6 x 1.0 x 25mm Hex Washer Hd #10 Flat Washer #10 Lock Washer 10-24 Hex Nut 10-24 x 5/8 Hex Soc. Button Hd 5/16-18 Lock Nut 5/16-18 x 1 Hex Capscrew

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63947 A3
1. Remove the 6 front skid pan bolts, and set aside. Remove the plastic grab bar cover from the grab bar. 2. Remove the six upper fasteners attaching the front grab bar, and set aside. 3. Loosen two lower fasteners attaching the front grab bar (do not remove). 4. Pull front grab bar away from ATV, and allow to hang forward of the unit. 5. Place winch mount into position inside of the front grab bar. 6. Place u-bolt spacer into position between the front winch mount mounting holes, and place u-bolt over the front grab bar cross bar, through spacer, into front winch mount slotted holes. Secure using flat washer, and lock nut. Hand tighten only at this time.
2.5ci Mounting Location 3.0ci Mounting Location
7. Move winch mount to ensure holes in the winch mount line-up closely with the holes in the grab bar winch mounting tabs. NOTE: The mounting location for the 2.5ci and 3.0ci winch are different, see middle picture at right for proper mounting location. 2.5ci Mounting 8. Place winch and fairlead plate into position. NOTE: Tilt motor side slightly to get upper winch electrical connector under grab bar support bar. 9. Secure using 4, 5/16-18 x 1.00 winch mount bolts and lock washers. 10. Tighten u-bolts securely at this time to 7 ft. lbs. of torque. NOTE: The 5/16-18 bolts and lock washers will be found in the hardware kit that came with the winch.

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Tighten fasteners to 17 ft. lbs. of torque. 3.0ci Mounting 11. Secure rear of mounting plate to ATV frame tab extensions using 2, 5/16-18 x 1.00 hex head screws, 2 5/16-18 lock nuts and 2, 5/16 flat washer. Attach winch to mounting plate using 5/16-18 x 1.00 hex head bolts found in hardware kit with winch. 12. Tighten u-bolts securely at this time to 7 ft. lbs. of torque. 13. Attach the extension plate to the bottom tab on grab bar cover (400 Kodiak only). Use the 10-24 x 5\8 button head, flat washers, lock washer and hex nut. Torque should be 2 ft. lbs. NOTE: The extension plate does not need to be used on the 450 Kodiak application.
14. Attach the grab bar cover to the grab bar using the 6M x 1.0 x 25mm hex washer head bolt. Do not over tighten; just snug the bolt up until the plastic grab bar tab starts move under the pressure. 15. Lift grab bar and secure into position using the six upper fasteners removed in step #2. Tighten 10 ft. lbs. of torque. 16. Tighten two lower grab bar fasteners loosened in step #3. Tighten to 10 ft. lbs. of torque. 17. Reinstall six skidpan fasteners removed in step #1. Tighten to 7 ft. lbs. of torque.

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