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Discussion Starter #1
Going down the gravel road, and this happens. Quick parts price check and we're looking at $180, or so. About a month ago, the exhaust fell out, and had to be taken home. Thankfully I live in a rural area where there are a lot of nice folks. Gotten two rides home recently.

I bought this thing because I was sick of wrenching on my cheap chinese buggies.
 

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Discussion Starter #2
Got the U-joints out. Not sure if I can save the driveshaft or not. Might be able to build it up with weld, and then shape it back into place, but unsure how strong it's going to be. That part is $81.

The only warning I had was that this thing started to shudder a little bit on acceleration the last couple rides. Everything looked good, so how do you prevent this??
 

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That thing has taken a beating! I don't have U-joints on mine, so I'll defer any suggestions! Only one I could offer is an aftermarket U-Joint with a grease fitting. Not sure what is available. Keep the faith Ron, all machines suffer the same fate at one time or another.
 

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Ouch!

Been a rough year this year!

Hope you can get yours up and running quickly and affordably!

I would suggest less wheelies! ;P
 

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That can be built up with a Weld. A good weld will be stronger that the original metal. A MIG would be Ideal, But unless you own a welder, $81 for a new one might be the way to go.
 

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That can be built up with a Weld. A good weld will be stronger that the original metal. A MIG would be Ideal, But unless you own a welder, $81 for a new one might be the way to go.
Have a MIG and started the process of building it up. Will need the front yoke, and two u-joints. Man, they were bad. And looks like they were bad for a while. Can't believe I didn't notice that.
 

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Don't be too hard on yourself, Nobody knows they need windshield wipers until it rains! lol
 

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Wow! that made me run out and look at mine. It's still there but I think there might be a slight play in the bearings on my joint, and I'll check it again tomorrow when I have some daylight.
 

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Discussion Starter #9
There is something more concerning here than just the u-joint failure. There's a cross brace in the frame that holds the lower mount for the rear differential. Both welds were torn away from the frame. It looks like that happened before this mess, but I can't tell for sure. It's kinduva what came first, the chicken or the egg discussion. I don't have a pic of it yet. It is possible as the u-joints were failing, that was sending quite a lot of vibration towards the rear differential, and that was too much stress for those welds. IDK. I'll have to run a longer bead on those, or maybe add some gussets to beef it up.

Parts are on order. Country Cat is offering free ground shipping right now. My parts order was $108, but I had a few other items that I needed. All in all, I think the repair for this failure is going to cost about $82.
 

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Hard to say, but I'd guess the driveshaft had to be creating havoc running down the trail!
 

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If it were mine, I would guess that I drank too much, hit a big rock, cracked the welds on the diff support and that put strain and a bad angle on the U joints!....Just saying:D
 

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a big C Clamp and a couple sockets properly sized will do the job , or go to auto zone and borrow a u joint / ball joint press
 
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a big C Clamp and a couple sockets properly sized will do the job , or go to auto zone and borrow a u joint / ball joint press
I'll have to see if our NAPA has one, when I needed one changed on my truck I pulled the driveshaft and took it to a local shop and he changed it for 20 bucks. I did find a joint with a grease zerk but as long as the factory one has lasted on mine I don't know if it's necessary.
19-1003-Ref5: ATV Rear Drive Shaft Differential Side U-Joint | ATV Parts | MFG Supply
 
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try Auto Zone type stores also as they advertise tool crib lending
 

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For me AutoZone is a 60 mile round trip, so with a 120 miles to pick up the tool and return I'd rather pay the shop to replace it. There is an O'Reilly's in the next town I can check if NAPA doesn't have one.
 

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Oh any any trip to the city result in taking the wife to the mall and to some overpriced place to eat. Don't mind going out to eat but tired of going to the same shopping mall.
 

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Discussion Starter #18
You guys are really overthinking this. >:) All you need is a workbench, a BDH (or BFH, whichever you prefer), a socket, needle nose pliers, and some patience.

Here's a vid on replacing u-joints on a Jeep. Same theory, just that the clips on mine were on the inside and a little harder to get out. You can dremel them out if you're not planning to reuse them.

 

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Does the yoke of the diff side just pull out? The parts break down shows a cap but no bolt, I was thinking the yoke was bolted and the only way to remove it is to remove the u-joint first since all 4 caps are pressed in. If that's the case I can remove the rear brake and pull the whole yoke and u-joint assembly.
 

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I think you are correct!
 
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