TBD. My PO'ed level is subsiding.
My theory:
- water is entering the dropout assemblies, left side failed suddenly (although the seal failure and moisture entry were occuring for some time), right side o-rings is in place but leaking and a support bearing failure is imminent
- the sealing system consists of double lip grease seals at the pinion against a hardened surface, orings for the axle (static), and orings for the reciprocating drive plate face against bare aluminum
- the oring is suitable for a static seal, but for a rotating one in our conditions they are not durable enough, combine that with the notorious fork seal eating clay we have, and early failure is going to occur
- left side dropout drive plate sealing o-ring was MIA (likely destroyed), the other wore flush, and support bearing grenaded and outer steel race spun in slip fit machine aluminum pocket
- the debris went through the ring and pinion, cracking teeth and embedding, and bearing debris and/or clay also scored the sealing faces
- the ring and pinion jamming with ball bearings going through it caused the clutch to pop and crack (iirc this occured violently on a hill climb), and also caused the headset spider gearset to lock up and possibly is why I smoked a tree (bars would not turn freely)
Good news:
- the left dropout housing cleaned up OK (filing nicks, emery cloth, 3m)
- Christini is warranty overnighting an overhaul kit for both lowers, and the clutch friction bits and a shaft to set torque
- all the remaining friction in the system is gone with the dropouts removed
- I am confident I can reassemble this
, and I am learning how to reman the whole system, although I expected this was more of a winter, in front of the TV, after then end of a season thing
- the system gives you some friction feedback through the bars and drive system warning of degradation, maybe just not enough notice if failure is occuring rapidly
- in a failure, switching AWD out generally lets you get going, excepting the ring and pinion in the dropout impacting the steering; hard to explain, but even if its disengaged at the transfer case the other side R&P have to rotate freely to allow steering, but I suspect the action of the one way clutch in the front hub can impede this, I could turn right fine but left was a problem (smoked tree on right side of left turn)
Not so sure of:
- was told to file the ring and pinion and run it with the chips (still has 3 tooth contact so strong enough), got it going smooth after working them with my mini fileset so aside from appearance should be ok
- the drive plate seal surface scoring - will buff with a 3M pad hope not to open clearances
- if either doesn't last I'll demand new replacements
- finding a lot of dry grease seals and voids free of packing grease, possible assembly error (wasn't me I grease the sludge out of anything I assemble), now have been through it all, s/b ok
- need to look in front axle hub see if those orings are holding, there no evidence of water through axle seal and bearing inspection
- dualsport durability, baja run, the the main reason I bought the 6 speed 530, prolly fine if reman'd and grease packed before and run in 1wd most of time, carry spare o-rings
Other thoughts on improvement:
- more frequent inspection (yay frick not complicated but more time)
- oilcan of ATF or something for lubing the driveplate seals every ride, maybe chain lube
- I am looking for sealing o-rings with better durometer ratings (buna-N or polyeurethane)
- ordering new drive/seal plates and having them smooth anodized
- this is the big one: adding a grease fitting as there is a machined passage almost all the way to the outside of the dropout assembly, might require drilling the ring gear plate to get the grease to the problem o-rings though, have to look closer PACK THAT MOFO AFTER EVERY RIDE
- bearings and seals can be ordered locally, but Christini air overnight to my office works too
Lemons, lemonade: Removal of parts to do this troubleshooting and service lets me install the remote choke (transfer case out) and new full length forkskins anyhow.
Carb seems to work well, good economy, no bog, plug a bit black so leaving it alone.
AWD shifts were getting problematic, calbe routing was an issue but the bigger cause is likely the system being jammed up with bearing bits!
"SERENITY NOW"
http://www.youtube.com/watch?v=5513mXmQbw4
This might need more frequent inspection, although never had an issue with it until the dropout bound up.
) to make the clutch output adapter, basket holder is just some scrap bar stock ground flat to fit the basket input.
