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Old 08-15-2019, 02:15 PM   #21 (permalink)
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Here's a couple of interesting links that will be useful for the R&R:The 1st link is an '04' Warrior with slightly different parts.
The 2nd link is equivalent to your year but also includes the R&R of the oil tank which isn't pertinent for your repair but has some excellent photos and dialog.

IMO the task at hand is NOT a complicated repair at all. You'll just need basic metric tools.

The most difficult task you have is loosening the secondary drive spindle crush nut, Item #44 (on transmission output shaft).
An impact wrench would do the deed or alternately a helping hand restraining the middle shaft with a plumbers wrench or large channel locks.
gl
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Old 08-16-2019, 11:21 AM   #22 (permalink)
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Originally Posted by alanh View Post
That middle shaft is chatarra (scrap) and wont work even if you flip the front pulley around. There aren't enough threads on the shaft to torque the pulley nut and go for a ride to 7 Eleven.

The close fit of the pulley & middle shaft splines is very critical as is the torque value so if you purchase used parts you'll want to do your due diligence.

Bottom shaft in photo is new design middle shaft that fits your ride



Middle Shaft Replacement '04' Warrior
I'm getting ready to purchase parts for the fix and though I have not disassembled anything on the bike yet, it looks like the current shaft on my bike has a lot less thread on it than the one pictured above for the pulley to connect to. I think mine looks more like the top shaft rather than the bottom one pictured above. I have an 06' and if I understand the material and threads I've read the last couple days, my bike should already have the new design correct? Or is the "new design" the OEM replacement part that's available now?
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Old 08-16-2019, 11:42 AM   #23 (permalink)
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Quote:
Originally Posted by Zmann View Post
I'm getting ready to purchase parts for the fix and though I have not disassembled anything on the bike yet, it looks like the current shaft on my bike has a lot less thread on it than the one pictured above for the pulley to connect to. I think mine looks more like the top shaft rather than the bottom one pictured above. I have an 06' and if I understand the material and threads I've read the last couple days, my bike should already have the new design correct? Or is the "new design" the OEM replacement part that's available now?
Order for your year and above otherwise you'll have to order other parts to make the earlier shaft usable in your bike.
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Old 08-16-2019, 02:53 PM   #24 (permalink)
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Like Alan stated, the bottom shaft is the one for 06 and newer.
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Old 08-27-2019, 01:36 PM   #25 (permalink)
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All my parts have arrived, the bike is dismantled and everything is cleaned and ready for the install. I have a couple quick questions before getting at it tonight. Thanks for the help with this!

  1. The YSM shows the Conical Spring Washer has been replaced with a "new" part which is the Tabbed Washer. When I ordered the part from Partzilla, #45, they sent the OEM washer not the "new" one. I assume I will be ok with this for now but should I plan on ordering and replacing that or wait to see if there is an issue in the future and replace it then? Also, should I have contacted them directly for the updated replacement or did they make a mistake with what was sent?
  2. When I replace the transfer case gasket do I need to do anything to the surfaces other that having them completely clean? The seal is made via compression with the proper torque on the bolts correct?
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Old 08-27-2019, 02:30 PM   #26 (permalink)
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Originally Posted by Zmann View Post
All my parts have arrived, the bike is dismantled and everything is cleaned and ready for the install. I have a couple quick questions before getting at it tonight. Thanks for the help with this!

  1. The YSM shows the Conical Spring Washer has been replaced with a "new" part which is the Tabbed Washer. When I ordered the part from Partzilla, #45, they sent the OEM washer not the "new" one. I assume I will be ok with this for now but should I plan on ordering and replacing that or wait to see if there is an issue in the future and replace it then? Also, should I have contacted them directly for the updated replacement or did they make a mistake with what was sent?
  2. When I replace the transfer case gasket do I need to do anything to the surfaces other that having them completely clean? The seal is made via compression with the proper torque on the bolts correct?
Which washer here are you talking about? https://www.partzilla.com/catalog/ya...dle-drive-gear
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Old 08-27-2019, 02:39 PM   #27 (permalink)
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Quote:
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Which washer here are you talking about? https://www.partzilla.com/catalog/ya...dle-drive-gear
Its part #45, on the main drive sprocket.
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Old 08-27-2019, 03:02 PM   #28 (permalink)
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Quote:
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Its part #45, on the main drive sprocket.
The manual is saying to replace it with a new one and not use the old one. Your fine with the new one you got. As for the gasket just have everything clean and torque to spec for the seal.
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Old 08-27-2019, 03:35 PM   #29 (permalink)
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#45 is the correct washer for an 06 up. If it looks gear shaped in the center hole you have the 05 and later and it will not work right.
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Old 09-01-2019, 08:47 PM   #30 (permalink)
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Got the bike back together today and took it for a run! Everything seems to be working properly and there were no extra parts in the end! Finally getting to experience what Ivan's flash and the new 31T pulley feel like and i couldn't be happier, the bike feels completely different!
The install of the middle shaft and front pulley went really well. Honestly, the most difficult part of the entire project was getting the exhaust back on, which was a major pain in the a$$! Thank's for all the help on here, I greatly appreciate it!
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