Full Flight a Arms
Upgrading sport ATVs with Full Flight A-arms is one of the most popular suspension enhancements for riders seeking wider track width, superior high-speed cornering stability, and adjustable steering geometry. Factory sport quads such as the Yamaha Banshee, Raptor 700, YFZ450, and Honda TRX450R are engineered with conservative factory track widths and non-adjustable ball joints tailored for tight woods trails rather than aggressive dune carving or motocross tracks. Full Flight Racing control arms solve these handling limitations by providing heavy-duty extended tubular designs, commonly configured in plus-two-inch wider and plus-one-inch forward geometries. Fabricated from premium 4130 chromoly steel and equipped with heavy-duty spherical heim joints, these aftermarket arms allow racers and weekend trail enthusiasts to fine-tune camber, caster, and toe settings with remarkable precision.
Chromoly Engineering, Heim Joint Mechanics, and Track Width Geometry
The structural superiority of Full Flight control arms originates from their 4130 aircraft-grade chromoly tubular fabrication. Compared to mild carbon steel used in OEM control arms, chromoly delivers a substantially higher strength-to-weight ratio, allowing the arms to absorb punishing jump landings and rugged rock impacts without permanent bending. Full Flight arms are robotically TIG-welded and powder-coated in thick, impact-resistant finishes to resist roost chipping and chemical corrosion from muddy trail rides.
A defining characteristic of Full Flight A-arms is their reliance on heavy-duty 5/8-inch spherical rod ends, commonly called heim joints, rather than conventional pressed ball joints. Heim joints offer unrestricted articulation and extreme shear strength, eliminating the risk of sudden ball joint separation during violent impacts. Furthermore, threaded heim joint shanks enable riders to adjust camber and caster angles independently simply by loosening jam nuts and rotating the joints, tailoring steering feedback from twitchy motocross responsiveness to relaxed high-speed dune stability.
The comparison table below details specifications, track width increases, structural components, and suitable terrain applications for Full Flight A-arm kits.
| A-Arm Configuration | Width and Forward Offset | Material Construction | Joint Mechanism | Primary Riding Terrain |
|---|---|---|---|---|
| Standard Plus-Two (+2+0) | +2 Inches Per Side (Stock Forward) | 4130 Chromoly Steel | 5/8-Inch Teflon Heim Joints | Fast trail riding, GNCC woods racing |
| Plus-Two Plus-One (+2+1) | +2 Inches Wide, +1 Inch Forward | 4130 Chromoly Steel | 5/8-Inch Teflon Heim Joints | Dune riding, motocross, general racing |
| Plus-Three Plus-One (+3+1) | +3 Inches Wide, +1 Inch Forward | Heavy-Wall 4130 Chromoly | Heavy-Duty Rod Ends | Open desert racing, wide sand dunes |
| Long-Travel Edition | +2 to +3 Inches Extended | Gusseted 4130 Chromoly | High-Angle Spherical Bearings | Aggressive competitive motocross jumps |
| Economy Replacement | Stock Width and Geometry | DOM Tubular Steel | Standard Ball Joint Replacements | OEM utility and recreational riding |
Selecting the plus-two plus-one configuration expands front track width by four total inches while stretching wheelbase by one inch, dramatically reducing rollover tendencies during aggressive high-speed turns.
Suspension Setup, Camber Adjustments, and Routine Maintenance
Properly setting up Full Flight A-arms requires careful mechanical alignment after bolting the components to the ATV chassis. Camber angle, which dictates the vertical tilt of the front tires, should be dialed to roughly negative one to negative two degrees at ride height with the rider aboard. This negative tilt ensures that as the quad rolls into a high-speed berm or tight sand corner, the outside front tire stands perpendicular to the ground, maximizing the tire contact patch and eliminating understeer push.
Maintaining spherical heim joints differs significantly from servicing sealed rubber-booted factory ball joints. Because heim joints feature exposed Teflon or bronze races, they should be cleaned with clean water and coated with dry PTFE lubricant rather than sticky wet grease, which attracts abrasive trail sand and grit. Checking jam nuts for proper torque and inspecting tie rod extensions before every racing weekend ensures that the steering linkage remains tight and free of dangerous play.
Examine the alignment parameters and maintenance standards below to achieve optimal handling performance and extend the life of your aftermarket A-arms.
| Alignment Parameter | Recommended Setting | Riding Benefit | Inspection Method |
|---|---|---|---|
| Camber Angle | -1.0 to -2.0 Degrees | Maximizes tire traction in hard turns | Digital angle gauge on front rim face |
| Caster Angle | +4.0 to +6.0 Degrees | Maintains high-speed straight stability | Tilt angle of upper-to-lower heim joints |
| Toe Alignment | 1/8 to 1/4 Inch Toe-In | Crisp steering turn-in responsiveness | Measure front and rear of front tires |
| Heim Joint Lubricant | Dry PTFE or dry silicone spray | Prevents abrasive sand and silt adhesion | Spray after washing; avoid sticky grease |
| Jam Nut Torque | 65 to 70 ft-lbs with blue threadlocker | Prevents thread loosening under vibration | Check with open-end torque adapter |
Regular inspection of tie rod jam nuts and heim joint nylon liners ensures razor-sharp handling and prevents front-end wobbles at full throttle.
How to Install and Align Full Flight A-Arms in 4 Steps
A step-by-step mechanical guide to installing aftermarket chromoly A-arms, mounting tie rods, and setting up steering geometry on a sport quad.
Disassemble Front Brakes, Tie Rods, and Stock Arms
Elevate the ATV on a sturdy center stand. Remove front wheels, unbolt brake calipers, detach tie rod ends from steering knuckles, and remove factory upper and lower control arm pivot bolts.
Assemble Heim Joints and Mount Arms to Chassis
Thread jam nuts and 5/8-inch heim joints into the Full Flight A-arm bungs, setting equal thread exposure. Fasten the arms to the frame brackets using supplied misalignment spacers and factory pivot bolts.
Attach Extended Tie Rods and Reinstall Knuckles
Install the included extended tie rods to compensate for the wider track width. Mount the steering knuckles onto the upper and lower heim joint studs, torque castle nuts, and secure with fresh cotter pins.
Set Static Camber, Toe-In, and Tighten Jam Nuts
Compress the front suspension to normal ride height. Adjust heim joints to achieve negative 1.5 degrees camber and one-eighth inch toe-in. Torque all jam nuts to sixty-five foot-pounds with blue threadlocker.
Frequently Asked Questions (8 Questions Answered)
Q1: What is the main benefit of installing Full Flight A-arms?
The main benefit is widening the front track width by four total inches and pushing wheels one inch forward, which substantially increases cornering stability, eliminates body roll, and allows precise camber and caster adjustments.
Q2: Do Full Flight A-arms use ball joints or heim joints?
Full Flight A-arms predominantly utilize heavy-duty 5/8-inch chromoly heim joints (spherical rod ends) rather than conventional press-fit ball joints, providing greater strength, durability, and full alignment adjustability.
Q3: Can I use stock shocks with Full Flight plus-two A-arms?
Yes, standard Full Flight plus-two A-arms are engineered to work with OEM length shocks. However, because the wider stance increases shock leverage, you may need to increase spring preload or upgrade to aftermarket valved shocks for optimal damping.
Q4: Do I need longer brake lines when installing plus-two A-arms?
Yes, extending the track width by two inches per side typically stretches factory rubber brake hoses beyond safe limits. Installing extended stainless steel braided brake lines is strongly recommended.
Q5: What is the difference between plus-two plus-zero and plus-two plus-one arms?
Plus-two plus-zero adds two inches of width per side while maintaining stock wheel fore-aft position. Plus-two plus-one adds two inches of width per side and moves the front wheels one inch forward, which extends wheelbase for better hill-climbing stability.
Q6: How do you lubricate heim joints on ATV A-arms?
Use a dry PTFE or silicone spray lubricant. Avoid thick automotive chassis grease or WD-40, as wet lubricants attract sand, silt, and dust that prematurely grind away the internal Teflon races.
Q7: What material are Full Flight A-arms made of?
Full Flight A-arms are fabricated from heavy-duty 4130 chromoly steel tubing, which offers exceptional tensile strength, flex resilience, and impact resistance compared to standard mild steel.
Q8: How do I adjust camber on Full Flight A-arms?
Camber is adjusted by loosening the jam nuts on the upper heim joints and turning the rod ends in or out. Threading the upper joint inward creates negative camber, while threading it outward creates positive camber.
Final Thoughts & Key Takeaways
In conclusion, understanding full flight a arms provides essential clarity, practical strategies, and actionable advice. By incorporating these foundational insights, adhering to verified safety guidelines, and following structured best practices, you ensure reliable, long-term outcomes while preventing common mistakes. Stay informed, consult certified professionals when needed, and maintain consistent quality care.