Lockedbevel gears

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06Vinson
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2010/11/29 12:14:48 (permalink)

bevel gears

think i busted my bevels yesterday, got stuck in reverse heared a loud pop, but was still able to move in reverse while getting pulled out, then after a little while longer i was going threw another hole in low, and it poped again, this time making noise as if it was stuck between gears grinding, it makes the noise in all gears, 2wd or 4wd/ diff lock ect. it will still move but it will move like a foot then, feels like its locking up then move again and do the same thing. I was still able to pull it on and off the trailer under its on power. I know when the bevels go they usually go in reverse, hence why i think thats my problem. Wheres everyone getting there updated bevels at? When i look up the updated part numbers it says its a kit, what all will come with this "kit"? thanks
TIA guys 

05 dmax dually 22.5s
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    boosted again
    Mud Monster
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    Re:bevel gears 2010/11/29 12:17:00 (permalink)
    ^^^sorry guys posted under my buddies screen name....

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    bustedknuckles
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    Re:bevel gears 2010/11/29 12:21:43 (permalink)
    Not sure what all comes with the kit, but the worst thing you can do when you think you busted your bevels is what you did. When you keep riding, or even spinning the output shafts by pulling the bike you take a very big chance of destroying your cases. Before you buy anything you should probly tear it down and check out your damage.

    Alan

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    dreggsta
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    Re:bevel gears 2010/11/29 12:59:03 (permalink)
    i suspect that or diff failure. when my rear diff went i thot it was the bevels.

    If I say something that you don't like, that you assumed it to be how you interpreted it & you don't ask me to clarify what i meant then heck yeh, I meant it tripled how you took it.
     
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    QUIK660
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    Re:bevel gears 2010/11/29 13:22:27 (permalink)
    Locals bike did the same when it was the rear diff. but with you trying to back outta something in reverse and it popped.....imma et a wooden nickel on bevels. especially on a older model h1. hope it didnt get your cases too!!!!

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    SixOhh
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    Re:bevel gears 2010/11/29 14:44:22 (permalink)
    yep, never keep riding when something feels that catastrophic....
     
    the way u can tell if its bevels or not is u can look down at the CVt case and u will see the motor torque up as u drive and roll over that broken bevel tooth.  the bike should start and idle just fine.
     
    if u think its diffs then simply jack the bike up and roll it over by hand.

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    Re:bevel gears 2010/12/13 14:11:26 (permalink)
    finally got the ambition to take it apart and low and behold the bevels were busted, but it didnt eat up the case at all, all bearings look good, both gears are toast, the one on the case side is just chipped up, the bevel on the shaft is missing some teeth! so im glad i got lucky and didnt damage the cases at all.

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    truponycar2
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    Re:bevel gears 2010/12/13 16:08:09 (permalink)
    That's good news for you.  I am about to replace mine since they busted on my last ride.  Where are you getting the updated kit from?  How hard is it to split the cases?  What parts have to be removed from the motor?  I'm just trying to figure out what I'm about to get into!

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    GWC
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    Re:bevel gears 2010/12/13 20:18:32 (permalink)
    make sure you install all new bevel gear bearings when you update to the new style gears.
    gotta take the complete top end off both side covers and the complete right side of the motors, the crank does not have to come out just have to take the right case half off.

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    1badkittykat
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    Re:bevel gears 2010/12/13 20:21:31 (permalink)
    YEP^^^^^ DONT FORGET THE BEARING! I know some ppl that thought they're bearing was good, and the idiots didnt change it, and boom LOL

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    06Vinson
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    Re:bevel gears 2010/12/15 17:25:33 (permalink)
    is this thing fixed yet or what???

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    Re:bevel gears 2010/12/16 18:38:31 (permalink)
    what bearings do i need? i know ill need the one that has the 2 retaining screws/plates which is p/n: 0832-015, 0832-015 is for my 06 model, should i order one from a newer model so i get an updated one? what other one will i need? the one that rides behind the bevel gear on the shaft? im also going to order 2 more bearing retainers and drill and tap for 2 more...
    post edited by boosted again - 2010/12/16 18:46:02

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    Re:bevel gears 2010/12/16 20:34:03 (permalink)
    0830-116   Gasket, Clutch Cover
    0830-084   Gasket, Base
    0830-085   Gasket, Cylinder Head (0830-124)
    0412-338   Gasket, Exhaust Pipe
    0830-128   Gasket, Magneto Cover
    0826-100   Screw, Cap
    0822-010   Retainer, Bearing
    0830-043   Seal, Oil - Driven Shaft
    0832-016   Bearing, Driven Gear
    0832-077   Bearing (0832-015)
    so this is everything i should need to complete this minus the
    bevel gear kit Kit 0822-122 ??
     
    post edited by boosted again - 2010/12/16 20:38:38

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    Re:bevel gears 2010/12/18 14:05:04 (permalink)
    ??

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    GWC
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    Re:bevel gears 2010/12/18 16:24:44 (permalink)
    Looks like a good list to me..

    08 650H1 L.E.
    LimeGreen/Black, Rad racked, Dual 3" snorkels
    Custom 2.5" lift & MP shocks front,Polaris shocks
    Custom tie rods ;
    11:1 Wisco & WebCam 417, Dynatech CDI,AMR racing coil,Dyno jet kit
    400 oil cooler,Jet-Hot coated header & muffler
    Fully clutched BY:PSC: 4.0 gears
    Custom gauges & some Limegreen Strobes
    Sanny Bushings,Aluminum Skids, Set of 04 floor boards
    HL wheel spacer 1" & 1.5", Viper Max 3000
    29.5" Laws on ITP type 7s






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    truponycar2
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    Re:bevel gears 2010/12/20 09:51:22 (permalink)
    Is there anything else that should be done while it's torn apart?  Are any special tools required??

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    truponycar2
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    Re:bevel gears 2010/12/30 13:00:07 (permalink)
    boosted, did you get the parts yet?

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    GWC
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    Re:bevel gears 2010/12/30 14:32:39 (permalink)
    If it was me while it was down i would use a ball hone on the cylinder very very lightly and install a new set of rings, I would also install a 650H1 cam in it to boot since your taking the cam out anyway...
     
    I would also install new vavle guide seals if you have very many miles on it, cheap and easy to do while its apart.
    post edited by GWC - 2010/12/30 14:43:46

    08 650H1 L.E.
    LimeGreen/Black, Rad racked, Dual 3" snorkels
    Custom 2.5" lift & MP shocks front,Polaris shocks
    Custom tie rods ;
    11:1 Wisco & WebCam 417, Dynatech CDI,AMR racing coil,Dyno jet kit
    400 oil cooler,Jet-Hot coated header & muffler
    Fully clutched BY:PSC: 4.0 gears
    Custom gauges & some Limegreen Strobes
    Sanny Bushings,Aluminum Skids, Set of 04 floor boards
    HL wheel spacer 1" & 1.5", Viper Max 3000
    29.5" Laws on ITP type 7s






    #18
    Whitebandit
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    Re:bevel gears 2010/12/30 20:57:01 (permalink)
    Here is mine when I opened it up back in April



     
    This is after I replaced the bearing and gears


     

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    QUIK660
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    Re:bevel gears 2010/12/30 21:23:30 (permalink)
    james did you drill and tap those other two tabs?? i'll take pics of doing mine nxt wknd.

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    Re:bevel gears 2010/12/31 11:05:26 (permalink)
    Yes. I drilled and tap the other two. Im going to do the same with Kathys. I also j/b welded the bearing in the case also

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    Re:bevel gears 2010/12/31 12:31:01 (permalink)
    Has anyone ever tried to find a Thrust Bearing to replace the ball bearing thats in there???

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    Re:bevel gears 2010/12/31 13:08:30 (permalink)
    You mean a needle type bearing? Confused on what you mean by "thrust" bearing. If you could find a way to put a double rolled bearing in there it'll last forever!

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    Re:bevel gears 2010/12/31 13:12:27 (permalink)
    A thrust bearing is a bearing that rolls on an angle to offset the force being applied directionally. That may not be best though because the shaft technically rolls both ways....hmmmmm

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    Re:bevel gears 2010/12/31 13:45:16 (permalink)
    Oh......a tapered bearing. Was confused......it would work if you had a way to press it into the race. Isn't the fixed bevel shaft held from the back with some sort of nut?

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    Re:bevel gears 2010/12/31 15:03:51 (permalink)
    GWC

    If it was me while it was down i would use a ball hone on the cylinder very very lightly and install a new set of rings, I would also install a 650H1 cam in it to boot since your taking the cam out anyway...

    I would also install new vavle guide seals if you have very many miles on it, cheap and easy to do while its apart.


    Does the H1 cam make much of a difference? Is it worth $200?
    post edited by truponycar2 - 2010/12/31 15:05:49

    '12 Outty 1000 XT - Snorks, OL2's, /// and STM, HL 2" lift, HL springs, Xtreme LED bar, HL rad kit
     
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    Re:bevel gears 2011/01/01 18:47:34 (permalink)
    james you remember the tap size off the top of your head? i also got 2 more bolts/retainers, for mine...

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    Whitebandit
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    Re:bevel gears 2011/01/01 23:24:47 (permalink)
    boosted again

    james you remember the tap size off the top of your head? i also got 2 more bolts/retainers, for mine...


    Man I dont remember. I have a whole set of the taps so I just size the bolt to the tap.

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    Re:bevel gears 2011/01/06 15:22:30 (permalink)
    for anyone taping 2 more holes to hold the bearing in, the tap size is 6mmX1.00, use 5mm drill bit and remember to use lots of oil while taping it....

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    truponycar2
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    Re:bevel gears 2011/01/06 16:02:21 (permalink)
    Do you get much benefit from doing that?  Is it necessary?
     
    BTW, nice pic!  I like the black and yellow.  Looks good!!!
    post edited by truponycar2 - 2011/01/06 16:03:29

    '12 Outty 1000 XT - Snorks, OL2's, /// and STM, HL 2" lift, HL springs, Xtreme LED bar, HL rad kit
     
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