Whats up with this irregular track/bogey wheel wear? *pic inside*

ViperMike, this is what you're seeing inside the tunnel (pics below). As Steiner mentioned, it's the firm/soft adjustment assembly that mounts to left side of the tunnel.

I too feel like the wear is either from a mis-aligned track and/or the rear axle components aren't assembled in the correct orientation (as in that wheel isn't spaced out from the rail with the correct spacer) ??

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ViperMike, this is what you're seeing inside the tunnel (pics below). As Steiner mentioned, it's the firm/soft adjustment assembly that mounts to left side of the tunnel.

I too feel like the wear is either from a mis-aligned track and/or the rear axle components aren't assembled in the correct orientation (as in that wheel isn't spaced out from the rail with the correct spacer) ??

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yes that is exactly what is in my picture and what I feel could be broken but I do not think it would cause this track wear.

Any instructions around on how to check track alignment and rear wheel setup?
 
Start the sled, suspend the rear and spin the track. Let it stop naturally without using the brake. Look through the track windows and verify an equal distance between the track clips and the hyfax. If unequal, loosen (not remove) the rear axle nut and use track adjustment bolts to push/pull the axle. Snug axle nut, spin track and check again. Also, track alignment and track tension are inter-related. If you can't get 'er, I'd pull the skid and look it over.

The skid I'm showing is a CK 144, but should be the same 3 wheel rear axle assembly as your skid. The pics are for assembly orientation reference. You can also look at a parts fiche online.

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What is the condition of that bearing in the damaged rear wheel now, does it have any wobble in it? How tight was your track tension before your 600 mile ride? Just a couple of thoughts.
Northernsledder's pictures appear to be right on the money. Starting on the passenger side, you have a bolt, a washer, a wheel, approximately 1 3/4" collar, a washer, the frame(skid), a washer, the adjuster, approximately 6 1/2" collar, a wheel, approximately 1" collar, the adjuster, a washer, the frame(skid), a washer, approximately 1 3/4" collar, a wheel, a nut. The adjusters on each side, have a slight angle to them and angle out towards the outside of the track that they are on, so that you can access them through the window of your track, with a socket. I am saying "approximately" on the size of the collars because it is just from a visual, I did not measure them.
 
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I'd still run it. Just check it doesn't get worse in a hundred miles.
 
I'm thinking that the part number you are looking for is #85 Slider 1, 8FU-47441-11-00. I'm wondering why that lug is able to wear down into that slider because the the upper part of that slider supports the flat part of the track. Is it possible that the backer on the studs is wearing the upper portion of Slider 1 down, resulting in the drive lug dropping down and chewing the lower portion. Also, check to see if Slider 1 is loose or not.
 
It's all good, I figure if we throw enough suggestions out there, we'll eventually hit on a solution. I see that the damage to that wheel is at least an inch up the side of the wheel, and yet the lug on the track is only a 1/2 inch high. If the track was shifting over and doing the damage, you would think there would be some wear on the passenger side of the middle wheels also. Maybe have a look at those.
 
4th wheel kit installed and I still can't see anything that might be causing this issue. The only think is looks like the plastic piece that protects the shock adjuster has some damage but that wouldnt cause my rear boggy to tear apart if they were related.

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Drivers look ok?

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Well, if everything checks out (alignment good, no broken studs, no broken track clips, etc) it's probably safe to say something got wedged in there and chewed the track and wheel before it came out?? I wouldn't let the sun goes down on this though! Keep a close watch next time you have the sled out.
 
4th wheel kit installed. New outside rear wheels. Track tension and alignment set. Rode a few miles in my yard and everything seems find.

This is the only thing I found that could possibly cause the track damage. The stock adjuster cable protector. Although if I replaced it I would cause this problem to be worse so not sure what is going on.

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