Soo long story short tranny let go due to some bad bearings and ate it self for lunch:


the bearing, and because there was no support the main gears went all wonky and have been ground all to hell





So time to make a jackstaff setup that will let me keep 4wd:













the balance of the parts (1" shaft, #60 chain and sprockets for the drive, #50 for the front drive sprocket and the factory 520 for the rear drive). are shown below, I'll update as I go, also I will be using the sled secondary.

 

Going from 35hp to 120hp will put some additional stress on the tranny. But it must of been fun while it lasted. LOL

 

it's actually pushing closer to 150hp , and the biggest issue o what cause the tranny to go, is the rear axle bearing are in bad shape, and combine that with some slop in the swing arm bushings, the rear sprocket had at least an inch of wobble back and forth which worked on that bad bearing, then with that bearing gone, all hell broke loose lol.

 

Some ugly pics of metallic carnage. Eeewwww!

 

piece by piece its coming together, just tacking everything together till i have the clutch, new belt, and drive chains hooked up, starting with the driven clutch:

You can see where i cut the top rail for clearence for the driven clutch:



good overhead shot of how i have to position everything:



Lots more room for the carbs, and so far everything is nice and simple. I will be adding in extra braces once the main structure is in, and have it built so i can pull the parts out with interference:

 

a little progress tonight, still waiting on the clutch to get in before i weld anything up, but so far everything is looking pretty good:









I will have to do some clearencing for the chains to run without rubbing on the tubing, but thats no biggie, but i'll wait till i have the clutch (tuesday or so) and belt so i can ensure everything is running true.

 

looks like you have everything in hand...

 

I will only have everything in hand when i have it back in the trail, and time is a tickin lol still waiting on getting the secondary in, should be here tomorrow, also gotta figure out when i can make a trip to the popo dealer and pick up the new belt, and bunch of little pieces. Anyway i started on the mounts for the 4wd housing, I was able to extract the busted bolt, and bolted it back into the factory location, then on the bearing/input side i got started with fabbing up the mounts, nothing special just nice and simple:





I'm hoping I can get it going during my next set of days off (sunday through tuesday, i work way toooo much), so we'll see how it goes.

 

Recieved the clutch today, tossed it in place to see if i i need to trim a bit more of the frame back:





So i'll probably trim the frame back in the back just a bit, and a bit further foward, as a tight clearence will cause issues eventually, anyway more to come.

 

the 4wd gearbox mounts is finished, I'm in need of some nuts and bolts before i can continue on