Content Source: 2019 Timbersled ST 93 Ripper Owner’s Manual (9928777 R03) > Installation Chapter

IMPORTANT

The Owner's Manual for this vehicle contains warnings, instructions and other information you must read and fully understand before safely riding or performing maintenance on this vehicle.Always follow the warnings and instructions in Owner's Manual.

Click the CONTENTS link above for the Table Of Contents, or download a full PDF of the Owner Manual in the Owner Support area of Polaris.com

Installation Instructions

Motorcycle Disassembly:

NOTE
The disassembly process listed is universal for all bikes using the ST 93 Ripper kit. This process may vary slightly between makes and models. Refer to your host bike’s owner’s manual for specific references and disassembly procedures.
  1. Place bike on a stand or suitable support where both wheels are off the ground. Secure properly to prevent bike from tipping when wheels are removed.(An adjustable stand is helpful for reassembly.)
  2. Remove the seat and side panels.
  3. Remove chain by disconnecting master link.
  4. Remove the rear brake lever from frame and let hang (this includes the spring).
  5. Remove upper rear shock bolt or pin.
    NOTE

    Keep upper shock bolt for later use as this item will be reinstalled.
  6. Remove the rear swing arm bolt (this will drop the entire swing arm assembly off the bike) and remove the shock, tire, brake, and swing arm assembly from the bike as a complete unit.
    NOTE

    It is recommended to cable tie all bushings, spacers, etc. to their corresponding parts at all pivoting points to prevent losing any parts during storage.

  7. Remove the front brake lever and cable retainer bolts from the bikes front forks. (On some models use the provided cable tie to secure start button).
  8. Loosen the front axle bolt and remove the front wheel.
    NOTE

    Keep front axle bolt for later use, this item will be reinstalled.
  9. Remove the front drive sprocket and sprocket cover.
  10. Check to ensure all previous steps are complete. You are now ready to start the assembly portion of the process.

Rear Ripper Assembly

 

Left Side

Right side

Spacer Spec.

Part #

Spacer Spec.

Part #

Honda

0.80 mm

5141218

6.87 mm

5141219

Kawasaki

N/A

N/A

N/A

N/A

Yamaha

N/A

N/A

15 mm

5141220

*Left and Right as positioned sitting on the bike
  1. Locate rear track assembly and position it up to the rear swing arm bolt location on the bike. Some fit kits will require spacers on one or either side of the frame, located between the Ripper frame mount brackets and the bike’s swing-arm bolt bracket location. See table at the beginning of this section for specific bike model spacers.
    NOTE

    Kawasaki KLX models do not require any spacers. Honda CRF models require left and right swing arm bolt spacers/reducers. Yamaha TTR models require a single spacer positioned on the right side of the bike.

    Image
  2. Slide provided 7/16” x 6-1/2” swing arm bolt in from the left hand side of the bike and tighten lock nut to listed torque specification.
    TORQUE

    54 Nm (40 Ft. Lbs)
  3. Bolt the lower portion of the strut rod to the kit assembly using the provided M 10 x 40mm bolt . DO NOT TIGHTEN until after upper portion of strut rod has been bolted in place.
  4. See note below before continuing.
    NOTE

    KAWASAKI MODELS ONLY skip Step 4 and complete Steps 5 and 6. For Honda and Yamaha models continue with Step 4.

    Bolt upper portion of the strut rod into the bike’s upper shock bracket using the bike’s upper shock mount bolt or pin. For bikes using a bolt, torque to the bike manufacturer’s specifications. Once you have the upper portion of the strut rod in place, torque the lower portion of the strut rod to the specification listed below.
    TORQUE

    60 Nm (44 Ft. Lbs)
    For Honda and Yamaha models continue to the Brake Line Assembly and Routing section.
  5. See note below before continuing.
    NOTE

    This step includes the upper strut rod installation and brake line routing for Kawasaki models only.
    Once you’ve completed Step 3 and before you fasten the upper strut rod bolt, move the strut rod up to provide enough clearance, feed the brake line and master cylinder over top of the rear right sub-frame tubing of the bike and under the gas tank as seen in the image below. Now move the top of the strut rod down back into place lining up the mounting holes. Image
    NOTE

    Some Kawasaki models can use secondary bolt hole in the strut rod for lower ride height.

    Bolt in place using the original upper strut rod bolt or pin and torque to the bike manufacturer’s specifications. Once you have the upper portion of the strut rod in place, torque the lower portion of the strut rod to the specification listed below.

    TORQUE

    60 Nm (44 Ft. Lbs)
  6. Keeping all of the slack out of the brake line, fasten the brake line to the top and the bottom of the strut rod with provided cable ties in the locations indicated in the image below. Image
    WARNING

    When routing brake lines it is critical that you keep all brake lines away from any surfaces, such as engine or exhaust, that can become hot while operating the vehicle. Failure to comply will adversely affect the vehicles brake system and may lead to severe injury or death.

  7. Run the brake line forward under the bottom of the gas tank along the main frame of the bike towards the bike’s front neck-tube. Make sure there is a minimum of one inch of clearance between the brake line and the lower head set turning stop posts to prevent the brake line from being pinched. Place another cable tie around the brake line fastening it to the bike’s throttle cable keeper bracket . The remaining brake line can free hang up to the master cylinder mounted on the right handle bar. Adjust the pitch of the brake lever, ensuring it is easily reached and easy to pull. Tighten the brake lever perch hand tight being careful to not strip the mounting perch threads. If needed, you can loop any remaining slack in the brake line in between the right fork tube upper and the neck-tube of the bike frame as seen in the photo below. (Honda model shown for reference)Image
    WARNING

    When routing brake lines, make sure there is a minimum of one inch of clearance between the brake line and the lower head set turning stop posts to prevent the brake line from being pinched. Failure to comply will adversely affect the vehicles brake system and may lead to severe injury or death.

    For Kawasaki models, once you have completed Step 7 continue to the Drive Chain and Sprocket Assembly section.

Brake Line Assembly and Routing

WARNING
When routing brake lines it is critical that you keep all brake lines away from any surfaces, such as engine or exhaust, that can become hot while operating the vehicle. Failure to comply will adversely affect the vehicles brake system and may lead to severe injury or death.
  • Yamaha Models
    NOTE

    Refer to images of Honda model for routing references.
    • For the Yamaha TTR models, run the brake line forward either on top of the strut rod or located parallel against the left hand side of the strut rod. Secure the brake line to the strut rod with a cable tie located at the top of the strut rod and one at the bottom of the strut rod in a similar fashion to the photo for the Honda model. From here feed the brake line and master cylinder to the right side of the bike feeding the brake line between the bike’s upper sub-frame column and the wiring harness brackets on the frame. This will help hold the brake line against the bikes frame and as far away from the exhaust system as possible. From here route the brake line forward towards the front of the bike underneath the bikes fuel tank. Place another cable tie near the front of the bike securing the brake line to the bikes lower horizontal frame tube.
    WARNING

    When routing brake lines, make sure there is a minimum of one inch of clearance between the brake line and the lower head set turning stop posts to prevent the brake line from being pinched. Failure to comply will adversely affect the vehicles brake system and may lead to severe injury or death.

    Image
  • Honda Models
    • Remove the two rear gas tank bolts and loosen the front tank bolt on the bike. Lift up on the rear of the gas tank giving yourself enough room to feed the brake line and master cylinder over top of the rear right sub-frame tubing of the bike and under the gas tank as indicated in the image below Feed the brake line forward under the bottom of the gas tank along the main frame of the bike. Keeping all of the slack out of the brake line fasten the brake line to the top and the bottom of the strut rod with cable ties as shown . Reinstall the two rear gas tank bolts previously removed and torque to bike manufacturers specification. Next, torque the front tank bolt to manufacturers specifications. See image below for brake line routing reference : Image
    • Near the front of the bike where the brake line is approaching the front neck tube of the bike, cable tie the brake line to the front gas tank frame mount and another cable tie to the bikes frame-mounted wire harness on the bike’s neck tube. See photo below for cable tie locations . The remaining brake line can free hang up to the master cylinder mounted on the right handle bar. Adjust the pitch of the brake lever, ensuring it is easily reached and easy to pull. Tighten the brake lever perch hand tight being careful to not strip the mounting perch threads. See image below:
      WARNING

      When routing brake lines, make sure there is a minimum of one inch of clearance between the brake line and the lower head set turning stop posts to prevent the brake line from being pinched. Failure to comply will adversely affect the vehicles brake system and may lead to severe injury or death.

      Image

Drive Chain and Sprocket Assembly

  1. Install provided sprocket and bearing carrier housing onto transmission output shaft. Make sure to use Blue Loctite® 243 on the provided 3 button head screws . HONDA ONLY: Place provided spacer onto output shaft before installing sprocket.
    NOTE

    Reference you host bikes owner’s manual or manufacturers specifications for proper torque specifications.
    Image
  2. Tighten sprocket backer plate to the engine case and torque to bike manufacturers specifications before chain is installed and chain tension is set.
  3. Route chain around both sprockets.
  4. Complete the assembly of the chain with the master link provided. Be sure to install the master link with the opening of the link facing rearward in relation to the chain direction.
  5. Set the proper chain tension by loosening chain slider nut and bolt. Slide the chain slider up or down until 1/2”-5/8” of vertical deflection is met in the upper chord of the drive chain. Torque chain slider nut to specification below when proper tension is achieved.
    TORQUE

    25 Nm (18 Ft. Lbs)
    NOTE

    Chain will stretch within the first 5hrs. You will want to check for proper chain tension. Chain slider is not intended to roll and can be rotated as needed to keep proper chain tension on usable surface of slider.

Front Ski and Spindle Assembly

 

Left Side

Right side

RDCR Spec.

Part #

RDCR Spec.

Part #

Honda

18.03 mm

5141390

25.4 mm

5141389

Kawasaki

17.35 mm

5141392

17.35 mm

5141392

Yamaha

14.91 mm

5141394

20.49 mm

5141393

*Left and Right as positioned sitting on the bike
  1. Locate the front ski , spindle , ski rubber , and provided hardware.Image
  2. Place the Ski Rubber on top of the center of the ski with the indicated “Front” of the Ski Rubber towards the front tip of the Ski.Image
  3. Place the lower portion of the Spindle on top of the Ski Rubber in the ski saddle to where the Fork Clamp support bracket would be positioned behind the front forks of the bike. Line up the bottom bolt hole and insert the M 10 x 155 mm bolt . ImageApply nut to bolt and torque to specification listed below.
    TORQUE

    45 Nm (33 Ft. Lbs)
    WARNING

    Failure to torque fasteners as directed will adversely affect the steering system and may lead to severe injury or death.
  4. Insert front spindle reducers into spindle . These will change per bike manufacturer. Your individual bike model fit kit will come with the appropriate spindle reducers/spacers, see the table at beginning of this section for spindle reducer placement for your specific bike model.Image
  5. Use existing front axle bolt to attach the front spindle to the forks .ImageFor now, just snug the front axle bolt, do not tighten until after step 6.
  6. Using the composite fork clamp (fork clamp halves are identical), place one half of the fork clamp in front of the fork tubes with the concave portions sitting around the face of the lower fork tube. Take the other half and mate it around the back side of the fork tubes between the fork tubes and the spindle backer plate. Take the Fork Clamp washer plate and place it over the face of the front fork clamp lining up the bolt holes of the washer plate with the clamp.ImageUsing Qty.–2, M8 x 75mm bolts supplied with your kit, insert bolt through the washer plate, both halves of the fork clamp, and through the spindle backer plate. Apply the supplied M8 locking nuts and torque to specification listed below.
    TORQUE

    20 Nm (15 Ft. Lbs)
  7. Tighten front axle bolt .
    IMPORTANT

    Refer to manufacturers specifications for proper torque setting.
  8. Check to ensure all previous steps are complete then move on to the rear cowling assembly section.

Rear Cowling Assembly

  1. Install the rear cowling with the provided, Qty.– 4, nylon rivet fasteners.. Image
  2. Slide cowling forward under bikes rear fender making sure the front left chain guard portion of the cowling is positioned behind the Drive Sprocket Plate. Image
  3. Start with the front left side mounting hole . Insert nylon rivet fastener . Repeat process for the front right side mounting hole , inserting nylon rivet fastener securely.
    NOTE

    The rear cowling is pliable, the easiest process for lining up the rear fastener mounting holes of the skid frame with the cowling holes is to pull out on the bottom most part of the cowling in the middle of the molding. This will pull the rear hole in the cowling forward allowing you to line up the holes to insert the nylon rivet fastener.

  4. Repeat this process for both left then right rear mounting holes.
  5. Check to ensure all tools are accounted for and all steps have been completed in the proper order.

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