when DD is installed, it needs to be swallowed in using the bolts.
Hey guys I am a little late to this party but i am concerned. After doing some reading I decided to do the bearing upgrade. Ordered everything from BDX. Removed case cover only.Everything looked like new inside the DD case. Cleaned everything up as best i could. Installed new 5203 bearing on shaft. Trying to install cover back in and having troubles. I am about 1/8 from mating up with case. I know the the bearing is wider but not that much? What am i doing wrong? If machining is the answer I am a little confused as to what actually needs to be machined? I am guessing: on the shaft the bearing sits on, the collar the the bearing seats up against? So if i measure the old bearing/spacer together, measure the new bearing, then machine the difference off the shaft so the the new 5203 sits at the same height as the old one this should allow the case cover to mate up without cranking on the bolts and applying excessive side loading? Someone help me out.
Thanks
Brandon
2010 Arctic Cat M8 LE
I talk to Jeff from BDX today. As per his instructions, case went back together just fine. For clarification, at first i only had the cover off, he told me to remove the entire case. I would also recommend just doing this right away. It makes it easier to clean everything up. What he told me is that sometimes when the cover only is removed with the case still installed, the output shaft ( or sun gear) that spines to the trackshaft can get pushed outward. Making it impossible to mate the cover back up with case. This is why you should just start out by removing the entire case. Once out of the sled and cleaned up, make sure the output shaft it COMPLETELY seated into the case. I think this is where some people think they need to machine parts when they might not have to. Then reassemble the rest of the case, if it still does not go back together easily and completely you may have to machine the transfer gear shoulder. Also when installing the case back into the sled, if it doesnt seat completely and easily against the tunnel, you may have to machine the trackshaft. According to to Jeff from BDX, and most of the guys who seem to know what they are talking about in these forums, this is a case by case, sled by sled situation. I got lucky, everything went back together perfectly once the case was removed. As for the new bearing being wider, and sitting flush with the end of the transfer gear: again according to Jeff, this the way it suppose to be. The reason the 6203 bearing was prone to failure, other than it being only a single row bearing, was the spacing at the end of the shaft. Not sure why but that what i was told. So, with the case out, if everything mates back up, no machining required in my opinion. Again, every sled seams to be different, its just ****ty manufacturing practices by Arctic Cat and their suppliers. Hope this helps.