4th Wheel Kit Problem

[SchelT]

Just within the last two weeks I attempted to install a 4th wheel kit ( SMA-wheel-kt-05 20m) on my '14 XTX 1.75. Now I cannot torque down the axle nut because the outside collars are too long. Has anyone else experienced this problem? I followed all instructions correctly and reassembled exactly as the diagram shows in the repair manual. Can't understand why the collars are too long now. Any advise would be appreciated.

PS Hoping to not have to grind down or cut the collars

 

[weldion]

You should not be forced to cut or grind anything down with that kit. Take pictures and publish here and check everything really carefully before you cut anything.

 

[SchelT]

You should not be forced to cut or grind anything down with that kit. Take pictures and publish here and check everything really carefully before you cut anything.

I've already taken it apart two times, checked all spacers, flat washers, track tension adjuster orientation and even put the axle bolt in from the opposite side, still the same results. Utilizing supplied collars with the kit and factory. Still coming up short on axle bolt space to install the outside track wheels

 

[SchelT]

I've already taken it apart two times, checked all spacers, flat washers, track tension adjuster orientation and even put the axle bolt in from the opposite side, still the same results. Utilizing supplied collars with the kit and factory. Still coming up short on axle bolt space to install the outside track wheels

 

[weldion]

I do not know if this is to any help. This is how much of the axle that is sticking out when it's torqued on my sled.

 

[SchelT]

I do not know if this is to any help. This is how much of the axle that is sticking out when it's torqued on my sled.

 

[SchelT]

View attachment 109977

This is the installed kit. If you look at the left side, I have very little axle to put the outside track wheel and torque down the nut. All spacers in the middle are kit supplied. Outside spacers are original Yamaha supplied. Still can't figure what I did wrong

 

[Sevey]

There is definitely a problem. I installed the kit this summer and it all went together. There is a part here
( or two) that is not to spec. Did you measure the pieces to see if they are the same. They all should be symmetrical. Perhaps the wrong spacer was included.?
Ms

 

[SchelT]

There is definitely a problem. I installed the kit this summer and it all went together. There is a part here
( or two) that is not to spec. Did you measure the pieces to see if they are the same. They all should be symmetrical. Perhaps the wrong spacer was included.?
Ms

I haven't measured the collars. Compare to what specs? As far as the spacer, I assumed the kit was factory Yamaha and it would be an R&R installation.
So the general consensus is...something is definitely wrong and I should not have this issue. Without making any modifications

 

[R00STER]

Is that spacer on the outside of the rail the same size as the one on the other side?
But you should be using the stock spacers that you took off. Are you certain that you didn't mix up an inside and outside spacer?

 

[MrChetStuart]

While I see where your concern is coming from with regard to how much axle is visible, I'm also wondering if you actually put that last wheel on as far as it makes it onto the shaft and tightened everything up a bit to see what happens. You may think that those spacers, washers, bearings & adjusters are all tight against each other, but from my experience once the rear axle is disassembled completely during maintenance and then reassembled, the whole assembly doesn't settle into place until you get the nut on and wrench a little.

 

[weldion]

While I see where your concern is coming from with regard to how much axle is visible, I'm also wondering if you actually put that last wheel on as far as it makes it onto the shaft and tightened everything up a bit to see what happens. You may think that those spacers, washers, bearings & adjusters are all tight against each other, but from my experience once the rear axle is disassembled completely during maintenance and then reassembled, the whole assembly doesn't settle into place until you get the nut on and wrench a little.

I'm with you. Have you tried to tighten it down to close every little single gap between the collars on the axle? Try that and compare with the threads sticking out on the side of the nut on my axle.

 

[SchelT]

Is that spacer on the outside of the rail the same size as the one on the other side?
But you should be using the stock spacers that you took off. Are you certain that you didn't mix up an inside and outside spacer?

Yes both outside spacers are the same. I double checked before the 2nd reassemble. Inside spacers are very obvious. 1 long and 2 very short. Much
different than the outside

 

[SchelT]

While I see where your concern is coming from with regard to how much axle is visible, I'm also wondering if you actually put that last wheel on as far as it makes it onto the shaft and tightened everything up a bit to see what happens. You may think that those spacers, washers, bearings & adjusters are all tight against each other, but from my experience once the rear axle is disassembled completely during maintenance and then reassembled, the whole assembly doesn't settle into place until you get the nut on and wrench a little.

Yessir, I did try to tighten down the axle nut with all parts in place. And I noticed the nut was tightening against the wheel bearing instead of the axle shaft.
I didn't want to damage the bearing on the outside track wheel

 

[SchelT]

Not sure if this makes any difference but I did replace the stock axle guide wheels with two Yamaha (SMA-8EK38-02-RD) red wheels. I measured the inside bearing width of both the stock wheel and red. They are the same.