Achilles

Good luck Andrew--let me know if you run into any difficulties as I may be able to guide you through it. 

Thanks Frank-- can't wait to get her running again.  I didn't get any shots of the seal placement and wondering why the heck I didn't think of it!  I will try to take some shots of where I disconnected the rear end from the frame, etc., as well as the brake job I am dealing with.  I will try the grease tonight as well.  Hopefully it will come out relatively easily.

Thanks for the tip Frank--that's just what I did.  Used a propane torch on the pivots.  I wish I had thought of your wet rag idea but I didn't heat it long enough to heat the axle bearing I don't think, maybe less than a minute.  I then sprayed some more PB Blaster and gently worked the shoes back and forth (or up and down I should say!) with a short piece of 2x2 and a hammer.  I was eventually able to get them off.  The shoes have probably been seized a long time since they don't look too worn.  I will try to reuse them but definitely applying anti-seize before they go back on!  Now I just have to get the damn brake cam out and sand it down, apply some anti-seize etc. since it is stuck pretty good too.  It still turns with a pretty good whack on the cam lever but nowhere near easily enough for the cables to pull.  Do you know if I need to remove the cam lever by unbolting it or should the cam just pull out?  Thanks again!

I just completed this job and I did remove the rear end to get to the seal but not much to it.  Just had to support the rear diff (used a jack) and the quad with a cinder block and a few wood blocks under the frame near the motor.   I did everything per the manual except I did not remove the brake panel as it was seized on the axle pretty good. I unhooked the brake cables and just unbolted the rear shocks and suspension arms to remove.  Then I unbolted the seal hosing/holder from the subtransmission (4 allen bolts) and replaced the seal.  i also replaced the o-ring on the prop shaft.  The job went fairly smoothly but not sure if it solved my problem yet since I still have the right rear wheel off to service the brakes.  The shoes are rusted onto the pivot pins and I have been trying to work them off with some PB blaster and a prybar since they are seized on pretty good.  Any tip on removing these btw?

Yes that would be great, thanks Frank!  I am in WA so glad to hear he ships all over

Thanks for your reply MtBob--I will pull the axles and have a look

That's great to hear.  I have a 98 Bayou 300 4x4.  Trying to go through it now to see what I need to get her in good shape for work around the property,  Nice to know parts are available still

Really??  Why am I only hearing about these now haha  I need to plan to go soon

Looks like you got everything you need for a nice trek there!

That looks awesome. 

Hey I know this was posted some time ago but I was enjoying following the progress.  How did it work out in the end?

I'm hearing a clunking sound from the front end.  It doesn't happen when I bounce the front end up and down on the shocks while the motor is off--only when driving.  There is a small tear in the CV boot on the axle so I planned on replacing the boot.  Could a bad axel cause a clunking noise when thottling forward?

I checked the site and they have the owner's manual but not the service/repair manual.  Do you have experience working on this machine?  I am wondering whether parts are pricey/readily available. 

I haven't tried that site yet but I definitely will.  Thanks for the tip!  So far I really like the quad.  Runs pretty well so far but needs some work--to be expected on a '98!

Hi all, 

I purchased this quad from Craigslist somewhat against my better judgement due to the fact that the driveshaft boot was leaking oil.  I am assuming it is just the seal that needs replacement.  Does anyone know the part numbers for the seal and boot?  I am also trying to get a hold of a service manual for this so I am not going in blind!

Thanks for your help!