Snowmobileaddict 403 #1 Posted April 21, 2022 (edited) After spending some time with Pullstart's very informative thread on this failure point that all 5xi owners shoudl be aware of, I set about doing this same repair to my 522xi back in Fall 2021. If you are not familiar with the thread I refer to, here is a link: In late 2021 I coordinated with a small CNC machine shop and had a new pin and block made and I figured at some point I would have to get a friend with a welder to help me apply the repair as I do not own a welder. Here is the pin and block I had made up: In January and February of this year, as I anticpated getting around to this repair in spring, it ocurred to me that there may be a way for folks to get this repair done without having to get a welder involved. I figured I could take chance on seeing if an off the shelf Grade-8, 7/8" bolt might be able to take the place of the machined pin. The cost was cheap enough and the "aft" or rear hole was already 7/8" diameter so using a bolt would just require opening up the forward or front pivot pin hole a bit. I decided the cost to roll the dice on a bolt was well worth the cheap price of admission. The big bolt might just fit the cast iron axle perfectly and if it didn't, oh well, I'll use plan A and get ahold of a welder. I even planned on only slgihtly opening up the forward pivot pin hole in the frame and tapping it with 7/8"-9 tap in order to better secure the bolt if it happened to fit the cast iron axle. Two weeks ago I tore into the repair. After I pulled the cast iron axle out, I test-fit the grade 8 bolt. I couldn't belive it. The bolt actually fit the axle better than the machined pin did! So away I went. I opened up the front hole in the frame with a step bit and followed with a 49/64" bit and 7/8"-9 bottom tap. I'll add that I had to chase to the hole with the tap from both the front and the rear (both ways) to knock the swarf or left of cut pieces of metal off the back side of the threaded hole before the big 7/8" bolt would fit up and thread in from the rear hole. In the end it was a perfect fit. The smooth unthreaded portion (shank) of the bolt took up all the space between the frame member with a single washer under the head. I tighted it down and added a 7/8"-9 grade-8 lock nut. No play any more at the front or rear pin holes in the frame. It's like the bolt was meant for this repair. Just pure dumb luck. I think this repair will oulast me and if there is any issue down the line I can revisit this and do the weld-up repair as I already have the parts necessary to do so. Total cost to do the no-weld repair was about $42 in parts (exact McMaster Carr bill of materials is shown below) and drill bits and the thread tap. As comparision, I paid the machine shop $60 to make me the pin and block. I just wanted to put this out the 5xi community especially for those that want to do this repair but do not have access to a welder. Edited April 21, 2022 by Snowmobileaddict 8 Share this post Link to post Share on other sites
Pullstart 62,918 #2 Posted April 21, 2022 Great work! If you’re correct, that sure saves a lot of time manufacturing the parts and welding! 3 Share this post Link to post Share on other sites
JoeM 7,874 #3 Posted April 21, 2022 Nice looking deal Everyone of my xi machines needed that area addressed. I am lucky enough to have the welding ability and equipment. I do have a question is there anyway to lock the bolt from rotating? (making sure the axle turns on the bolt). I figure you got her pretty tight but, seems like in time it could relax a bit. 2 Share this post Link to post Share on other sites
Snowmobileaddict 403 #4 Posted April 21, 2022 (edited) So, the bolt is threaded into the front hole TIGHT and locked down TIGHT with a grade 8 lock nut to at least 100 lb*ft. That bolt is NOT turning, especailly given the front axle greasing intervals that I use. I'm really happy with how this turned out. Edited April 21, 2022 by Snowmobileaddict 6 2 Share this post Link to post Share on other sites
Roger R 448 #5 Posted April 22, 2022 Awesome... McMaster also has shoulder and other specialty bolts to match almost any application: IE more thread less shoulder / Less thread more shoulder etc. Not to endorse McMaster Carr, but I have had great experiences with them over the years. Anyone who does any shop work should have their sight book marked. 1 Share this post Link to post Share on other sites
Cee245 818 #6 Posted April 23, 2022 Looks excellent, and a great description!! 👍 1 Share this post Link to post Share on other sites
