MOD - NCY extension kit installation instructions

sanjuro62

Okay, this is one heinous install, but very much worth it:

Before installation make sure the bolts that hold the yellow bushing in place are flush to the extension kit arms. You're going to have to torque them down a bit.

I flipped the frame upside down and positioned everything in the picture below. Make sure you put a metal/rubber protective sandwich against the outer frame (where the frame bushing is located). Tighten the c-clamp enough to push the frame bushing outward. Only do enough to allow you to slide the extension arms in place.

Once you have the extension kit in place you will discover that the bolt holes for the frame bolts will not line up. The remedy is to take two c-clamps and torque the yellow bushing down until the holes line up. Do both sides as evenly as possible.

Once everything is lined up and the frame bolts are installed the bushing should be look as pictured below.

Now if you haven't damaged anything or pulled your hair out of frustration, then your frame with the extension kit should look like this:

Note: The rear shock extension mount should first be attached to the top of the shock absorber and torqued down. Then the two pieces should be bolted to the frame. I've found that the NCY supplied bolt is hard to get to via an allen socket key because the rear frame obscures part of the tool path.
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Doctavius · Posted: Thu Mar 01, 2007 9:56 pm Post subject:

Nice yellow bushing sandwich you've made there. Thanks for the info, I will be installing mine either this coming Sunday or Monday.... BTW you're color choice on your frame looks wicked!!
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ARunto · Posted: Thu Mar 01, 2007 10:02 pm Post subject:

nice frame color
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Dutch zoomer · Posted: Thu Mar 01, 2007 10:32 pm Post subject:

Can I do this installation without removing the whole engine?

Tuesday Club · Posted: Thu Mar 01, 2007 11:17 pm Post subject:

I would hope so....A lil more difficult, but very doable nonetheless...

I hope it goes easy, I ordered mine last week.
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Renzsu · Posted: Fri Mar 02, 2007 1:23 am Post subject:

It won't go easy, but it's possible..
Sanjuro, I have a question for you, those allen head bolts that come with the kit, I didn't use those to connect the kit with the frame, I re-used the stock bolts (in all the swearing and sweating and getting that thing to fit, I completely forgot the thing came with its own bolts). Do you know if that could cause problems or are they basically the same and is the only difference the actual head on the bolts?

sanjuro62 · Posted: Fri Mar 02, 2007 5:22 am Post subject:

sanjuro62 · Posted: Fri Mar 02, 2007 5:25 am Post subject:

Renzsu · Posted: Fri Mar 02, 2007 5:46 am Post subject:

PomeRuck · Posted: Fri Mar 02, 2007 10:43 pm Post subject:

that's beautiful!
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Renzsu · Posted: Sat Mar 03, 2007 2:11 am Post subject:

SJ, how did you bolt down that long bolt through the engine? The stock nut has some safety on it that breaks when you remove it (sorry, can't think of the proper English word for it). I guess you need a new one and be careful not to tighten it too much because it could bend then extension kit (the rubber bushings might be compressed too much?).

sanjuro62 · Posted: Sat Mar 03, 2007 7:09 am Post subject:

Doctavius · Posted: Mon Mar 05, 2007 11:22 pm Post subject:

I have done some things that were difficult in my life.... But that was one of the hardest things ever!!!! OMFG!!!!!
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Doctavius · Posted: Mon Mar 05, 2007 11:51 pm Post subject:

So I don't know if I am the only one that has noticed that the claw doesn't fit right on our frames???.. The weld on the nut side of the shock mount stops the claw from seating properly on the frame and allowing for the design to work correctly. I tested how it fit on the other side with the bolt sticking out and it became blazingly clear what had to be done..... So I went and grabbed my angle grinder and voila!!! It fit just great and offers a lower profile look than others have been acheiving with this frame extension. Final pics to come I am fucking exhuasted and my back is killing me!!! Here are some pics to ponder.....

Here you can see the weld I am talking about....

This shows how the "Claw should fit against the frame rail......

The angle and amount of material removed here is perfect!!!

Then a little emery paper to clean it up....

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Renzsu · Posted: Tue Mar 06, 2007 1:13 am Post subject:

Yeah, that's something I didn't do, but before I go out and drive this thing I might shave off that bit as well instead of letting the weld eat into it..