Stepney 2,325 #1 Posted February 25, 2020 Evening, all. Dragged a project out of the corner finally. An old Yamaha Big Bear 2wd ATV. It was put to pasture some years ago due to the splines on the solid rear axle being rounded off. She was run hard.. however like most old Yamahas, the engine and transmission still run perfectly. I found the axle pretty well rounded off, however the final drive gear still looks fairly decent on it's internal splined surface. I'm sure however, that it took some wear. Only will know when the new shaft turns up. The old machine will mostly be relegated to moving trailers and such in the yard, it'll never see trail running anymore. So I'm not too concerned about any sort of 'high speed' incident.. I have doubts it ever went over 20mph to start with. So. I've been considering, after new bearings and seals/what not, coating the new shaft and the old gear with JB Weld or some other epoxy, just to help remove any slop from the old splines. Some will weld the gears, however this is apparently a difficult process and should only be used as a last ditch effort. A new gear/spline run about the cost of a half decent WH with an implement to boot.. I just can't see having nearly $1,000 into a rear end on an otherwise shot old machine like this. So anyways. Has anyone tried such a thing? Share this post Link to post Share on other sites
WHX?? 48,783 #3 Posted February 25, 2020 And the are where??? Seriously first thought was OEM parts.. just my nature... yah then I remembered what oem parts go for. Any chance of boneyard parts? Let's ask @Digger he is a hard core ATV enthusiast. 1 Share this post Link to post Share on other sites
Stepney 2,325 #4 Posted February 25, 2020 Don't worry all, photos will come! Hahaha. Computer is having a tantrum tonight. I'd gladly replace it all with OEM .. but much of it is NLA, and NOS prices are through the roof. Looking at about 475 for the final drive gear, another 350 or so for an OEM axle, 125 a piece roughly for hubs. The old girl is built like a tank, if it were 4wd I'd almost do that. I did buy one boneyard final drive gear already to the tune of 175. It was worn worse than my original. 1 Share this post Link to post Share on other sites
Pullstart 62,795 #5 Posted February 25, 2020 Is this a chain drive or shaft drive rearend? Could you replace anything with go-kart parts or the like? Share this post Link to post Share on other sites
Stepney 2,325 #6 Posted February 25, 2020 11 minutes ago, pullstart said: Is this a chain drive or shaft drive rearend? Could you replace anything with go-kart parts or the like? Shaft driven I'm afraid. 1 Share this post Link to post Share on other sites
Pullstart 62,795 #7 Posted February 25, 2020 Hmm. Build your own 90 degree box and convert to chain? Share this post Link to post Share on other sites
bc.gold 3,403 #8 Posted February 25, 2020 (edited) Build up the missing spline by tif welding with a hard surfacing filler then have a new spine machined in by a shop that does EDM - Electrical Discharge Machining. Edited February 25, 2020 by bcgold Share this post Link to post Share on other sites
SylvanLakeWH 25,492 #9 Posted February 25, 2020 Given your description of intents / needed / desired uses, If you are only using it to move trailers and putz around the yard, hook it up and see how much wiggle there is... if relatively tight... just use it... 1 Share this post Link to post Share on other sites
