Bucksnot,


My Dad's AC 500 had a problem blowing the ignition fuse when turning left. The dealer couldn't find the problem (useless!!), I finally traced it down to a plug just under the plastic under the speedo. The wires go to the run\stop switch. The plug had come partially unplugged & the prongs were grounding out against a clip holding the wire loom. Hardest part of the fix was removing the front rack & plastic. I just plugged it back together put a zip tie around it to hold it tight & wrapped it with black tape. Hope this helps, also never had trouble with my clutch bearing & I've swamped the tranny once.

 

Otis500,
The snorkle works great. I bought a 3" to 1 1/2" rubber reducer at Menards and a 1 1/2" hose ($10.00), removed the old exhaust on the clutch cover and put the new one on. I also capped the one under the seat. Haven't got water in it since. Some one else on here posted it before and I can't remember the name, but Thanks.

CatLance,
Thanks for the info. I dropped it off at the dealer wed and they still haven't started on it yet. !*&%!!!ers I guess I'll be riding my big red this weekend

 

Also when replacing the bearings, put them in the freezerfor about 30 min. and they will just drop right in. Don't forget to put loctite on the bearing retainer screws. I was told to put neversieze on the shafts instead of grease. Hope it helps.

 

Removed my belt housing and am having a tough time removing the bearings.Used a blind bearing puller,heated the aluminum case and pulled like crazy until I busted off the little tabs on the end of the puller.Does everyone have this much trouble? If you did how did you finally get them out?
I am glad that I removed the cover to check the bearings after reading about the trouble others have had with theirs.They weren't completely shot but were just starting to go.I am going to replace them with a better quality possibly Timken bearing if I ever get the old ones out.

2001 AC 500 Auto

 

It sounds like the open bearing is unsuitable for the environment it's supposed to work in. If I were having a problem like this, I'd check with the local bearing supply house to see if they have a double sealed bearing to replace the open bearing.

 

The way I got mine out was to just heat the cover but be careful this will warp if you get it to hot, or melt if you don't keep the torch moving. I replaced mine with NTN 6303 LLBC3/5C, It is a beefier bearing the seals are of a higher grade also. The cost was about $13.00 each the prices vary alot so look around. You should also put antiseize on the cover where the bearing seats against it, This will keep the reaction from aluminum and steel from seizing the bearing. It will be easier to get out next time. The main thing is to keep the water & mud out of it. I would recomend putting a snorkle on the belt exhaust. Good luck.

 

I had to replace the bearings on my clutch cover at 400 mi, I ended up welding a blot head to the bearing and using a 10 lb slide hammer I got them out. I also had the ignition fuses blowing, it turned out to be a wire up where the handle bars go through the plastic had worn through and was grounding out.

 

I figured out how to get the bearings out of my housing.
First pack the hole in the center of the bearing really well with grease,fill it up completely and make sure that it gets underneath the bearing as well.Find a socket with an O.D. that fits nicely inside bearing I.D. Insert the socket into the bearing flat side down but first insert the proper sized extension into the open end of the socket and into its receptacle.Give it a couple of good whacks with a hammer and "voila " hydraulic pressure pops the bearing out lickety split.

 

Dumb question time (I'm good at those)

Cracker, How did you tell when your clutch cover bearing "went out"? I have a 2000 Auto with about 1500 miles on it. Its been through some fairly deep water and mud (well up on the side of the transmission case), but usually for short distances only. I have had the Cat get water in housing to point it slipped only once. That time, I really needed a boat, but thats another story (Rubicon, Sportsman 500, 450 ES all drowned out that day). Other than that, I have never really had any trouble with it, until last weekend - it started making a "whirring" noise, any time the engine is above idle, (when the clutch is spinning). The best way I can describe the sound is like a ball bearing rolling around in a metal can.

I pulled the plastic vent cover off, and the belt looks good - I have not ventured into taking off the aluminum case yet, but have guessed it was a bearing bad. Is that the way you knew yours was bad? The machine still seems to pull and perform OK, although last weekend (when I first noticed the noise) it did seem be struggling a bit, but I really assumed that was a due to riding double in a fairly spongy creek bottom. What do you think? Appreciate any help,

KYParrothead

 

Sure sounds like your bearing is out to me.