I took the u-joint apart AGAIN last night. Some of the needles had fallen out of one cap and were preventing the cap from seating properly. Since using the balljoint tool to put it all together was kind of a PITA, I brought it to the dealer at lunch. I'm glad I did! The yoke was bent slighly not allowing the caps to seat. So, they fixed it and I'll pick it up after work. $30 well spent IMHO.

 

Another update!

I installed the bearing carrier and U-Joint to the backside of the engine today (shims too!). I then poured in oil...no leaks. Then I fired the machines up and let it idle...no leaks! I'm very very very very happy to say the least!

Next step: install the new swingarm boot(pick it up tomorrow) and install the swingarm. Now here's an intersting tidbit. The right side of the swingarm has the normal set up..the bolt and the lock nut. The left side just has a large bolt..not lock nut. That has me a bit confused. The service manual indicates that both side should be the same. Anyone have any insight?

Side note: The service manager knows the father of the kid I bought the quad off of. The service manager was the guy who rebuilt the carb before it was sold. He said overall, it's a solid machine and was impressed with what I got it for.

 

Here's something interesting regarding the swingarm bolt. In the service manual, it shows them being identical. However, on Ronnie's and the Yamaha site, it shows the right side being the two part unit (pivot and lock nut) and the left side being the one part (bolt). The Yamaha site lists it as two different parts. I even looked up the breakdown for a 2005...same thing. So, looks like I have the correct bits, I'll just have to figure out how to properly adjust it.

 

I've done both my '96 and my '01 (had occasion to swap motors). I installed the left side to torque specs, then installed the right, using the allen key (hex key) in the bolt portion and then holding the hex key and tighten the ring nut. worked fine on both. Remember that you aren't tightening the bolts into the swingarm, only into the frame, the extending pin is all that goes into the swingarm. IF the bolts are tight, they are tight, you just have to make sure you can swing the arm freely and the bolts are tight.

 

Thanks! That will help quite a bit. What did you use to tighten the locknut while you held the pivot shaft in place with the allen wrench?

 

(You must have a job like mine where you can sit on ATV forums all day, sweet)

I used an open ended wrench on an angle until it was as snug as I could get it, then used the socket to get the torque to spec.

First time, it didn't work, the plastic cap wouldn't snap into place, next time it worked.

BTW: I'm anxious to see your photo journal that you refered to earlier, particularly around the bearing replacement stuff, I've got 2 to do but don't want to be without a bike for 2 weeks. [img]i/expressions/face-icon-small-smile.gif[/img]

 

Who me? LOL!

Cool, I'll give that a shot. Hopefully, it'll go smoothly.

I hope to out together something by next week. I think with a guide and some insight, you'll be able to get this don't pretty quickly. I ran into a few snags that hopefully the writeup will help you and others avoid.

 

I picked up the new boot at the dealer today. Since the swinger is still off, I "test fitted" the new boot. Wow, a heck of a lot smaller than the other one. It actually fits! I'm not sure if Yamaha changed the design or these stretch over time or what.

I'm going to be away from the compy for a few days. Monday I should be buttoning up the swingarm and taking this thing for a test ride!

 

I finished putting it all back together yesterday and took it for a test ride around the yard. Everything worked just great! No leaks that I could see and no funny noises.

The new boot fit much better than the old one! There was still a bit of a gap once the boot was installed, but that retainer ring thing took care of that once it was tightened up. I took a picture of the old boot next to the new one and the difference is a amazing. I don't know if Yamaha redesigned it or if they just swell and stretch over time.

The hardest part about getting the rear end on was alligning the shaft that connects the rear diff and the U joint with the u-joint. It's a "blind" job since it all takes place inside the swingarm tube. I actually had to have my wife help me. I put the swingarm up on my ATV jack and had the Wolverine supported by jackstands. I had her slowly bring the swingharm forward while I made sure things were linining up. I had to hold that u-joint so it would align with the shaft. It took a few attempts and a few height adjustments with the jack.

The swingarm bolts really weren't too difficult. I had to jockey with the swingarm a bit to make sure it was aligned. Once both sides were in and turned in a few turns, I torqued down the right side bolt all the way, then went to the right side. I torgqued down the "pin", then torqued down the lock nut.

I'm going to do my best to do that write up when I can. I have a bunch of pics that I need to resize and of course, the write up it's self.

If anyone has any questions, feel free to post here now. I have this thread set to notify me when someone replies.

 

I don't think you are supposed to torque the swingarm Pin, just the Nut on the side that has the separate pieces. I adjusted the pin so that there was no noticeable freeplay side - to- side, then torqued the nut. I could be wrong, but that's what I did. Maybe someone else will set us straight.