1998 Kawasaki Bayou 220 project

[MarkinAR]

That would work if rebuilding the diff, but I misunderstood what you have that needs fixing. I updated what I said above to reflect just replacing the axle bearings. I completely forgot there are bearings and seals at the ends of the axle on a Bayou. You'll need a blind bearing puller if you want to try without pulling the whole rear axle apart. And I don't know if that works for sure. 

Yeah, the guy in the 2nd link has it figured out. The guy that pulled everything was doing it by the manual. A manual always does it the hard way so you can check everything while its apart. I like the easy way. 

[1911Neil]

I think I'll try the blind puller first. I'll have to borrow one but I know a few people that will probably have something that will work.

[MarkinAR]

I rent tools from Autozone all the time for specialty stuff. 

[1911Neil]

@MarkinAR, thanks for the tool rental idea. I hadn't thought of that. I was able to rent (temporarily buy) a slide hammer and a claw type attachment from the neighborhood O'Reilly auto parts store. I started on the right side bearing and it only took a dozen or so medium pops with the slide hammer and the bearing came right out. I removed the seal and replaced the seal and bearing, no problem. (See my 2nd youtube video above starting at 3:30 to see what I'm talking about here)

I moved over to the left side and hooked up the slide hammer just like the other side. I gave it increasingly harder hits with the slide hammer and got zero movement so I ended up taking the left side axle tube off. After removing the seal and cleaning it up a bit, I found the problem. There is a big snap ring there. A better pair of snap ring pliers probably would have made removing that a quick job but I managed to get it out with my cheapies and a small screw driver. Putting in the new bearing and seal and putting everything back together was easy enough. One more job crossed off my list.

If anyone is looking at a rear wheel bearing job, I highly recommend the slide hammer trick. All you need is the slide hammer with the three point puller attachment, a 3/4" washer (don't want to mess up your hub nut washer), and a pretty nice pair of snap ring pliers, plus the normal tools you'll need to remove seals and seat bearings and seals. I used a socket to seat the seals, the old bearing to hammer on to seat right side bearing and the bottom of a trailer hitch ball for the left side bearing.

[MarkinAR]

Right on, glad you got it knocked out. Keep up the good work and you'll have one good as new. 

[Arizona]

On 5/11/2020 at 6:28 PM, 1911Neil said:

I ended up just buying this. Should have it by the weekend.

Where did you find that connector and the terminals? Gotta link. Thanks

[1911Neil]

1 hour ago, Arizona said:

Where did you find that connector and the terminals? Gotta link. Thanks

https://cycleterminal.com/
Fast shipping and I think he sent like 7 connectors in case I messed up a couple.  I used one to replace a connection on my neutral safety relay. 
 

I hope posting links isn’t against the rules.