Front differential essentials :
Drain plug :
5mm hex wrench
O-ring : Rubber .
Approximate size :
OD - 11 mm
ID - 9 mm
Thickness - 2 mm
Thread OD - 9.81 mm
Pitch 1.0 mm
Fill plug :
6mm hex wrench
Copper flat crush washer
ID - 15.09 mm
OD - 18 mm
(Approximate) thickness - 1.27 mm
Thread OD - 13.75 mm
Pitch 1.5 mm

Rear Differential essentials :
Drain plug :
5mm Hex wrench
0.9 metric pitch
OD of threads / 9.62mm or 0.379"
Fill plug :
6mm Hex wrench
1.5 metric pitch
Thread OD 13.77mm or 0.542"
Washer : OD 18.10mm / ID 14.31mm / Thickness 1.29mm

 

Front differential essentials :
Drain plug :
5mm hex wrench
O-ring : Rubber .
Approximate size :
OD - 11 mm
ID - 9 mm
Thickness - 2 mm
Thread OD - 9.81 mm
Pitch 1.0 mm
Fill plug :
6mm hex wrench
Copper flat crush washer
ID - 15.09 mm
OD - 18 mm
(Approximate) thickness - 1.27 mm
Thread OD - 13.75 mm
Pitch 1.5 mm

View attachment 119822

View attachment 119823



View attachment 119824

View attachment 119825

And I thought I was anal with my fall maintenance

 

I will update this as jobs are completed....

Can am ultrasonic (small) parts washer. This is the manual (shake) version.

View attachment 119815

That coffee looks funny.

 

Its definitely decaf. Gotta be.

 

I just ride mine all year

 

Rear swaybar bushings :
All cleaned up and waiting for the new Garage Products kit to show up ....

 

That doesn't look heavy 😄

 

Pulled the front swaybar and bushings toady , shimmed a bit of clearance out of them , cleaned everything up and reinstalled. Drained rear diff fluid and I will add the plus dimensions to the above post tomorrow.
PS : Garage Products does not make replacements for the front (probably because the Zerks thread directlyinto the plastic).

 

Axles & differential out for seal replacement . Ever since the first day I rode this machine , there has always been a stain (no drips) at the input side of the diff . All I can come up with is that it was assembled dry and it burnt the seal within the first few miles .
Two tiny grooves on the yoke were removed with emery paper and now is smooth . Ordering seal today and spark plugs .
That should complete this and then will be ready for next April !.
Tick-tock tick-tock.....

 

Nice job Angore.

 

Like the dog said after his tail got caught in the door , " it won't be long now ".

 

New Garage Products swaybar & end-link bushings fit perfectly.
I had to add my own spin on the link connectors.

 

Time for some housekeeping and an afternoon break .

 

Wow!!!

 

Killing it, man!

 

 

I could send you a pair of those if you need it 🤣

 

This should probably go in the G2 fixes thread but the fact that BRP made no effort to secure the weep-hole overflow hose always bugged me. Finally decided to cut 2 small slots in the leading edge of the factory skid . Now it's (sort of) out of harms way . 2 small zip-ties finished it off , I ran out of red ones 🤣.

 

We're coming along nicely .

 

Primary is in good shape.
Small flats on the rollers , I turned them 180° for reassembly.
Hardly any button wear.
One way bearings are sealed on both sides. They roll smooth and firm. All items marked before disassembley.
I washed the spring cup , friction washer , one way sleeve & primary spring in hot soapy water . The springs & caps in gasoline.

 

Looking good.

 

I like your style! Keeping it fresh! So many people wouldn't even think to do what your accomplishing but if you take care of you stuff it will take care of you. I applaud your efforts and thanks for sharing!

 

I also did a FULL complete fall maintenance and/or do this every 1,000km.

I already replaced my bushings with GPs but front sway bar with OEM.
Replaced rollers and buttons on primary.
All the rest was perfect. Few KMs from reaching 6,000km and no leaks yet anywhere.
Every maintenance (1,000km) I also go through every connectors and wires and check if there's no corrosion, if there loose or check for chaffing signs.

Here's the final touch 😉

 

^^Satisfaction....priceless.