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Turbo Twister

New to me 2002 TRX450 S

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If you change the oil most oil filters will come with the larger o ring that goes on the cover.  There's a smaller oring up where the cap juts out that might be missing as well.  That one doesn't come with new filters.

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We received new front drive shafts two days ago from Niche Industries. I fitted them yesterday, refitted the knuckles and replaced the outer track rod ends. Today I had a look at the hubs and specifically the High Lifter wheel bolt and disc carriers which are supposed to be a press fit into the hubs. My problem is that the splines do not match. I drove one bolt in about 1.5 mm but could not get it in any further. I took it out again and measured across the splines on the bolt. The measurement on the old bolt is 10.48mm and that of the new is 10.86 mm. What should I do to make the bolts fit? It would be relatively easy to reduce the diameter of the splined part of the bolt but if I do this and subsequently need to change the hubs I could be faced with the problem of bolts being loose in the new hubs.

 

Has anyone else had this problem and if so how did they fix it?  Picture of old and new bolts attached.

Old v new wheel bolts.jpg

Edited by Bluezulu49
Fat finger spelling error correction.
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14 minutes ago, Bluezulu49 said:

We received new front drive shafts two days ago from Niche Industries. I fitted them yesterday, refitted the knuckles and replaced the outer track rod ends. Today I had a look at the hubs and specifically the High Lifter wheel bolt and disc carriers which are supposed to be a press fit into the hubs. My problem is that the splines do not match. I drove one bolt in about 1.5 mm but could not get it in any further. I took it out again and measured across the splines on the bolt. The measurement on the old bolt is 10.48mm and that of the new is 10.86 mm. What should I do to make the bolts fit? It would be relatively easy to reduce the diameter of the splined part of the bolt but if I do this and subsequently need to change the hubs I could be faced with the problem of bolts being loose in the new hubs.

 

Has anyone else had this problem and if so how did they fix it?  Picture of old and new bolts attached.

Old v new wheel bolts.jpg

 @shadetree  is the Highlifter specialist  ---  I'm a SuperATV guy 

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Just to be sure I measured all of the new bolts and they were pretty uniform at 10.85mm so the one I tried to install is not an outlier. In the meantime I will try freezing them to see how much they contract.

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So Turbo came home this evening and we decided to attack the hubs. He produced a 10.5mm hss drill bit and we bored out the holes in the hubs. We pressed the new wheel studs partly in using a vice and then drove them home by resting a lump hammer on the inside of the stud and hitting it with another lump hammer. This drove all of the studs hopme and so the rebuild can continue.

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Update on the bike! Dad has been quite busy with the brakes on the 450 and what a job he's doing. He has the brake pads and discs on now and the wheels are fitting as they should. He attempted to bleed the brakes today but unfortunately cannot seem to get any pressure build up, so we will have to troubleshoot that issue.

 

I have lots of work to do on the plastics and mud guards in the coming weeks, as most of the clips that bolt it all together are damaged or missing completely. I finish work in a week so will have a bit more time to work on it🤞

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I am not a  Highlifter  conversion kit guy , I only have SuperATV ,  something don't look right in this pic , see where the hub mates with the ring , big gap on the bottom and nothing on top 

image.png

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