1 / 2 S o c k e t W r e n c h 8 C r e s c e n t W r e n c h S m a l l R a t T a i l F i l e E l e c t r i c D r i l l 1 / 8 A l l e n W r e n c h
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1 Hidden CTI Line Kit Installation Instructions O v e r v i e w - C o n v e r t i n g o u r w h e e l s t o a c c e p t t h e H i d d e n L i n e C T I K i t i s a r e l a t i v e l y s i m p l e p r o c e s s. I t e n t a i l s o n l y t h r e e s i m p l e s t e p s. 1. D r i l l a n 1 1 / 3 2 h o l e i n t h e r i m a t t h e l o c a t i o n s h o w n. 2. T a p t h e 1 1 / 3 2 h o l e w i t h a 1 / 8 N P T p i p e t a p. 3. U s i n g a 3 / 1 6 o r 1 / 2 r o t a r y f i l e r o u t a s l o t n o m o r e t h a n 1 / 2 d e e p a s s h o w n i n t h e p h o t o. Tools Required 1 / 2 S o c k e t W r e n c h 8 C r e s c e n t W r e n c h S m a l l R a t T a i l F i l e E l e c t r i c D r i l l 1 / 8 A l l e n W r e n c h P a g e 1 o f 5
2 Cutting/Routing the b raided line feed through U s i n g t h e 3 / 1 6 o r 1 / 2 r o t a r y f i l e, c u t t h e s l o t a s s h o w n, a n d o p p o s i t e t h e v a l v e h o l e a r e a, a n d b e t w e e n t h e l u g h o l e s t o a d e p t h n o m o r e t h a n 1 / 2. O n 1 7 w h e e l s t h e r e a r e n o d e p r e s s i o n s b e t w e e n t h e l u g h o l e s s o t h e s l o t m u s t b e l o n g e r! T h e s e p h o t o s h a v e b e e n s h o w n f i r s t a n d p e r h a p s s l i g h t l y o u t o f s e q u e n c e s o t h a t y o u c a n s e e w h a t t h e e n d r e s u l t s h o u l d l o o k l i k e a f t e r y o u h a v e c o m p l e t e d t h e n e x t s t e p. N o t e t h a t t h e p o s i t i o n o f t h e m a l e / m a l e s t a i n l e s s f i t t i n g n e e d s t o b e c e n t e r e d b e t w e e n t h e h o l e s i n t h e w h e e l a n d d i r e c t l y b e l o w t h e s l o t y o u h a v e j u s t c u t o n t h e b a c k s i d e o f t h e p i l o t h o l e o f t h e w h e e l. R e a d a n d u n d e r s t a n d t h e n e x t s t e p s b e f o r e y o u s t a r t d r i l l i n g. I l i k e s e l l i n g w h e e l s, b u t i d o n t w a n t t o s e l l y o u o n e b e c a u s e y o u d r i l l e d a h o l e i n t h e w r o n g p l a c e. P a g e 2 o f 5
3 Drilling the air hole in the rim! H o l e m u s t b e c e n t e r e d o n o n e o f t h e r e c e s s e d s l o t s b e t w e e n h o l e s i n t h e w h e e l. T h e p o s i t i o n o f t h i s h o l e i s c r i t i c a l, s o m a k e s u r e t h a t t h e h o l e t h a t y o u a r e d r i l l i n g i s i n t h e s a m e p o s i t i o n a s p i c t u r e d N o t e t h e a p p r o x i m a t e d i s t a n c e t h a t t h e 1 1 / 3 2 d r i l l e d h o l e m u s t b e f r o m t h e r i m d r o p d o w n a n d s a f e t y b e a d i n o r d e r f o r t h e h o l e t o b e p o s i t i o n e d p r o p e r l y o n t h e i n s i d e o f t h e w h e e l. N o t e t h a t t h e h o l e i s v e r y c l o s e t o t h e r a d i u s. P a g e 3 o f 5 B a c k s i d e o f w h e e l a f t e r i n s t a l l. A f t e r d r i l l i n g, t a p t h e h o l e f r o m t h e s i d e s h o w n i n t h e p h o t o o n t h e t o p l e f t a n d u s e e i t h e r t e f l o n t a p e o r e q u i v a l e n t w h e n i n s t a l l i n g t h e m a l e / m a l e a d a p t e r.
4 Ready to install the wheel on the vehicle? I n s t a l l t h e t w o 7 / 1 6 t o r e d u c e r s i n t o t w o o p p o s i t e h o l e s a n d t h e m a l e n i p p l e f o r t h e q u i c k r e l e a s e a s s h o w n a b o v e. I n s t a l l t h e s m a l l o - r i n g s o n t o t h e b a c k o f t h e a i r v a l v e f i l l e r p l u g a n d i n s t a l l t h e p l u g s i n t h e w h e e l w i t h t h e f l a t w a s h e r, l o c k w a s h e r, a n d n u t p r o v i d e d. W h e n p u t t i n g t h e w h e e l o n t h e h u b, Y O U M U S T m a k e s u r e t h a t t h e l i n e i s n o t o n l y i n t h e s p a c e b e t w e e n t h e l u g s, b u t i t M U S T c o m e t h r o u g h o n e o f t h e t w o l a r g e r f l a t a r e a s. O n e o f t h o s e a r e a s i s s h o w n i n t h e p i c t u r e a t t o p l e f t a n d o n t o p o f t h e o f t h e h u b. O n 1 7 w h e e l s y o u M U S T m a k e s u r e t h a t t h e s l o t i s l o n g e n o u g h s o t h a t t h e l i n e i s n o t c r u s h e d. I f y o u f a i l t o d o t h i s, y o u w i l l c r u s h t h e b r a i d e d l i n e!!!!!!!! P a g e 4 o f 5
5 Finishing the install and parts list! O n c e t h e s e p a r t s a r e i n s t a l l e d, y o u m e r e l y a t t a c h t h e b r a i d e d C T I l i n e r u n i t u p t h r o u g h t h e p i l o t h o l e o f t h e w h e e l, l a y i n g t h e l i n e i n t h e s l o t a n d m o u n t t h e t i r e a n d w h e e l o n t h e v e h i c l e. O n c e o n t h e v e h i c l e, y o u s i m p l y l e t t h e l i n e l o o p a r o u n d i n a c i r c l e, p l u g t h e q u i c k r e l e a s e o n t o t h e m a l e f i t t i n g a l r e a d y i n s t a l l e d. P u t t h e b i g O - R i n g s o n t h e C e n t e r C a p s, s l i d e t h e c a p o v e r t h e C T I p a r t s b y t u r n i n g i t s l o w l y t o c l e a r t h e l i n e s, a n d a l i g n t h e h o l e s i n t h e c a p w i t h t h e r e d u c e r p l u g s, s c r e w t h e A l l e n s c r e w s t h r o u g h t h e c a p a n d i n t o t h e r e d u c e r s a n d y o u r r e a d y t o g o. P a r t s L i s t C e n t e r c a p s, C T I L i n e s, M a l e / M a l e a d a p t e r s, L a r g e O - r i n g s, S m a l l O - R i n g s, A i r V a l v e F i l l e r P l u g s, F l a t W a s h e r s, L o c k W a s h e r s, & N u t s. 8 - R e d u c e r P l u g s, & X 1 3 / 4 A l l e n S c r e w s. H I N T S - G r e a s e t h e t h r e a d s o n t h e r e d u c e r p l u g s. G r e a s e t h e s m a l l O - R i n g s f o r a b e t t e r s e a l. Y o u m a y n e e d t o l o o s e n t h e C T I l i n e o n t h e b a c k o f t h e w h e e l s l i g h t l y i n o r d e r t o g e t t h e l o o p t o l o o k l i k e t h e p h o t o t o p r i g h t. D o n o t o v e r t i g h t e n t h e R e d u c e r P l u g s! D o n o t o v e r t i g h t e n t h e A l l e n H e a d S c r e w s! P a g e 5 o f 5
6 Hidden Line Conversion For 17 Wheels I n o r d e r t o m a c h i n e t h e n e c e s s a r y s l o t i n t h e 1 7 w h e e l t o a c c e p t t h e h i d d e n l i n e a n d k i t, y o u w i l l n e e d t o u s e a n a n g l e d r i l l s i m i l a r t o t h e M a k i t a p i c t u r e d. Fo r t h e d r i l l i n g o f t h e s l o t a r e a t o b e m a c h i n e d, y o u c a n u s e a s t a n d a r d 1 / 2 d r i l l m o t o r. To o l s R e q u i r e d I n A d d i t i o n To T h o s e F o r T h e W h e e l s - 1 / 2 S t a n d a r d D r i l l M o t o r 1 / 2 B a l l H e a d R o t a r y F i l e 3 / 8 A n g l e D r i l l M o t o r 1 / / 3 2 D r i l l B i t s 1 M a s k i n g T a p e C e n t e r P u n c h M a r k t h e s l o t a r e a a s s h o w n. T h e d o t s a r e p l a c e d s o t h a t t h e 1 3 / 3 2 d r i l l b i t h o l e w i l l o v e r l a p e a c h o t h e r w h e n d r i l l e d. C e n t e r p u n c h t h e m a r k s a n d d r i l l e a c h h o l e s t a r t i n g w i t h t h e 1 / 8 h o l e a n d w i t h e v e n l y s p a c e d d r i l l s i z e s u p t o 1 3 / 3 2 a s s h o w n. D r i l l a l l h o l e s w i t h w i t h e a c h s i z e b i t b e f o r e g o i n g t o t h e n e x t s i z e. T h e t h r e e p i c t u r e s w i t h s u c c e s s i v e l y l a r g e r h o l e s a r e s h o w n. W h e n d r i l l i n g, u s e e i t h e r a d r i l l s t o p o r t a p e a s s h o w n t o s t o p t h e h o l e d e p t h a t 3 / 8 a n d n o m o r e! M a k e s u r e t h a t t h e 1 3 / 3 2 h o l e f u r t h e s t f r o m t h e p i l o t h o l e s t a y s a t l e a s t 1 / 8 f r o m t h e e d g e o f t h e m o u n t i n g s u r f a c e a s p i c t u r e d. O n c e t h e h o l e s h a v e b e e n d r i l l e d, u s e t h e a n g l e d r i l l w i t h t h e 1 / 2 b a l l h e a d r o t a r y f i l e a n d s t a r t t o c r o s s d r i l l t h e s l o t a s s h o w n. P a g e 1 o f 3 f o r t h e 1 7 W h e e l
7 T h e r o t a r y f i l e s h o u l d b e d r i l l i n g s o t h a t i t i s j u s t j u s t b e l o w t h e l e v e l o f t h e w h e e l m o u n t i n g p a d. A f t e r y o u h a v e d r i l l e d a b o u t h a l f w a y i n t o t h e s l o t, y o u w i l l n e e d t o e x t e n d t h e b i t f a r e n o u g h o u t o f t h e e n d o f t h e c h u c k s o t h a t t h e r o t a r y f i l e r e a c h e s a l l t h e w a y i n t o t h e s l o t. A f t e r y o u h a v e c o m p l e t e l y c r o s s d r i l l e d w i t h t h e r o t a r y f i l e, y o u w i l l t h e n n e e d t o l i f t u p o n t h e d r i l l m o t o r s o t h a t t h e r o t a r y f i l e w i l l c u t t h e s l o t t h e s a m e w i d t h u p t h r o u g h t h e s l o t. O n c e t h a t h a s b e e n a c c o m p l i s h e d y o u w i l l h a v e t o u s e t h e r o t a r y f i l e t o c o n t i n u e t o s m o o t h o u t t h e b o t t o m o f t h e s l o t s o t h a t i t i s t o t a l l y s m o o t h a n d n o e d g e s, h o l e s o r i m p e r f e c t i o n s a r e p r e s e n t. A t t h a t p o i n t t h e t o t a l d e p t h o f t h e s l o t s h o u l d b e n o m o r e t h a n 1 / 2 i n d e p t h. I t i s c r i t i c a l t h a t n o s q u a r e e d g e s a r e p r e s e n t a n d y o u m u s t f i l e a l l e d g e s!!!!! P a g e 2 o f 3 f o r t h e 1 7 W h e e l
8 A f t e r f i n i s h i n g t h e s l o t f o r t h e b r a i d e d l i n e, a n g l e t h e d r i l l a s s h o w n i n t h e p h o t o s a n d r o u n d o f f t h e e n d s o f t h e s l o t b y m i t e r i n g t h o s e e n d s w i t h t h e r o t a r y f i l e. T h e i n s t a l l a t i o n o f t h e m a l e / m a l e a d a p t e r i s t h e s a m e a s f o r t h e w h e e l e x c e p t f o r t h e l o c a t i o n o f t h e h o l e d r i l l e d. N o t i c e t h a t t h e d r i l l e d h o l e c e n t e r i s 1 1 / 8 d o w n f r o m t h e s a f e t y b e a d d r o p d o w n a r e a, i s a l i g n e d i n t h e c e n t e r o f t h e w h e e l h o l e s, i s i n l i n e w i t h t h e s l o t a n d o n t h e o p p o s i t e s i d e o f t h e w h e e l v a l v e h o l e. T h i s s h o u l d c o m p l e t e t h e w o r k n e c e s s a r y t o i n s t a l l t h e h i d d e n l i n e C T I K i t o n t h e 1 7 w h e e l. A l l o t h e r i n s t r u c t i o n s a r e c o n t a i n e d i n t h e p r e v i o u s i n s t a l l p a g e s. P a g e 3 o f 3 f o r t h e 1 7 W h e e l
INSTALLATION INSTRUCTIONS ATV PLOW ACCESSORY Plow Mounting Kit:Warn PN Application:2002 and newer+ Suzuki Eiger 400
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