1985 250SX Swing arm bearing replacement

[BigRedGrizzly]

Hi all... Just noticed this movement and clunky sounds at the swing arm. I think the bearing is beat. I plan to replace them. I understand a special tool is needed to remove the ring on the bolt on the right side. Just wondering is anybody has any tips before I get started.
https://vimeo.com/156489001

[3is4Fun]

I did the repair back in the early 90s, just used a hammer and flathead screwdriver to remove the ring that screws in and holds the bearings in place. It was fairly easy to do. I would like to have the tool however, it would make it that much easier.

[Chopsaw]

Not that hard to do . I used a punch and a hammer to get it loose . I cut 2 fingers on a socket to spin it off . If its tight spray it and let it soak for a while .

Chop

[ps2fixer]

Just a fair warning, check how rusty it is first. If it is rusty, get the tool, and soak it a few times with some penetrating fluid. An impact might help as well if you don't have one of them 300 ft/lb ones (the special tool isn't that strong sadly).

I have had a couple of machines that I couldn't get the ring nut off from even with the special tool. I haven't used heat on them yet though, last chance for those frames (being parted out), just to save the swing arms.

[BigRedGrizzly]

Just a fair warning, check how rusty it is first. If it is rusty, get the tool, and soak it a few times with some penetrating fluid. An impact might help as well if you don't have one of them 300 ft/lb ones (the special tool isn't that strong sadly).

I have had a couple of machines that I couldn't get the ring nut off from even with the special tool. I haven't used heat on them yet though, last chance for those frames (being parted out), just to save the swing arms.

Hi guys.. Swing arm will come out easily. I can't seem to figure out how to disengage the drive shaft. Does it just slide off?
https://vimeo.com/156974091

[ps2fixer]

Yea nothing holds the drive shaft on, the 250sx is spring loaded in the driveshaft + rear diff, the 250es is only spring loaded in the diff.

It has been a while since I swapped out the rear diff on my cousin's 250sx, but I think the route I took to disassemble was remove axle, unbolt rear diff bolts, and the diff should side right out. I know your not targeting the diff, but I slightly remember the drive shaft trying to slip out on me. My original target was to remove the swing arm, but got in the same situation. I think it binds too much that way, but could be wrong.

Here are a couple of photos to help show what you're dealing with inside there.

Output shaft on the engine: http://i.ebayimg.com/images/i/331476631319-0-1/s-l1000.jpg
SX Drive shaft (big end goes in the diff and you can see where it is sealed) - http://www.2040-parts.com/_content/items/images/91/336491/002.jpg
The big end of the drive shaft has a spring inside it pushing outward to keep the drive shaft tight, but couldn't find a pic of it.

[BigRedGrizzly]

Yea nothing holds the drive shaft on, the 250sx is spring loaded in the driveshaft + rear diff, the 250es is only spring loaded in the diff.

It has been a while since I swapped out the rear diff on my cousin's 250sx, but I think the route I took to disassemble was remove axle, unbolt rear diff bolts, and the diff should side right out. I know your not targeting the diff, but I slightly remember the drive shaft trying to slip out on me. My original target was to remove the swing arm, but got in the same situation. I think it binds too much that way, but could be wrong.

Here are a couple of photos to help show what you're dealing with inside there.

Output shaft on the engine: http://i.ebayimg.com/images/i/331476631319-0-1/s-l1000.jpg
SX Drive shaft (big end goes in the diff and you can see where it is sealed) - http://www.2040-parts.com/_content/items/images/91/336491/002.jpg
The big end of the drive shaft has a spring inside it pushing outward to keep the drive shaft tight, but couldn't find a pic of it.

Great... Thank you for the tips. Yeah, I was trying to avoid taking the axle and diff apart. It looks like I should be able to slide it back by compressing that spring. If I can't do that I suppose it will just all have to come apart. I can clean it and paint it up if that's the case.
Thanks again.

[ps2fixer]

The problem isn't so much if you can get it apart that way, the real problem is how do you put it back together in a controllable way with that tiny access hole with the boot fighting you all the way.

Axle is easy to remove if it isn't rusted like mad. Unbolt one of the hubs (right side I think) and make sure the axle collar comes off too, then slide the axle out to the right. Then the 8 diff bolts, 4 on the tube with the drive shaft, and 4 on the right side that hold it to the swing arm. Whole diff with the spacer tube should slide straight back and the drive shaft should be sitting there saying hello :).

The axle has a lot of stuff on splines, the ring gear, and the drum (for 85 models), so it might be a little bit hard to slide, but shouldn't be too bad. It never hurts to clean and repaint and reseal the axle tubes, that is a common spot for water to get in the diff once the bearing seals get shot. Axle tubes should be sealed with something, I'd use RTV personally and wipe off all excess to make it a clean install.

Sometimes more work is less work, same idea as preventive maintenance.

[BigRedGrizzly]

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Hammered

Yep... I'll be giving this the good treatment since its apart.

[BigRedGrizzly]

The problem isn't so much if you can get it apart that way, the real problem is how do you put it back together in a controllable way with that tiny access hole with the boot fighting you all the way.

Axle is easy to remove if it isn't rusted like mad. Unbolt one of the hubs (right side I think) and make sure the axle collar comes off too, then slide the axle out to the right. Then the 8 diff bolts, 4 on the tube with the drive shaft, and 4 on the right side that hold it to the swing arm. Whole diff with the spacer tube should slide straight back and the drive shaft should be sitting there saying hello :).

The axle has a lot of stuff on splines, the ring gear, and the drum (for 85 models), so it might be a little bit hard to slide, but shouldn't be too bad. It never hurts to clean and repaint and reseal the axle tubes, that is a common spot for water to get in the diff once the bearing seals get shot. Axle tubes should be sealed with something, I'd use RTV personally and wipe off all excess to make it a clean install.

Sometimes more work is less work, same idea as preventive maintenance.

I got the AllBalls replacement bearings. Do I need to pack them with extra grease. They definitely have some but when it came to grease I always thought more was better.

[BigRedGrizzly]

http://uploads.tapatalk-cdn.com/20160227/704da7d5a2b893742045c3391b40583b.jpg
I packed the hell out of them. [emoji1591]

[ps2fixer]

I don't see any issues packing them, not like your filling the diff with grease lol. Idk what kind of grease you used, but wheel bearing grease for boat trailers wouldn't be a bad idea, extra thick and tacky and is claimed to be water proof.

Either way, the old bearings look bad, with the shape they are in, i'd check your diff fluid atleast to make sure it don't have water. Either pull the drain plug and see if water comes out, or spin it over some by hand to mix it up well and check the fill cap and see if it looks milky.

[BigRedGrizzly]

I don't see any issues packing them, not like your filling the diff with grease lol. Idk what kind of grease you used, but wheel bearing grease for boat trailers wouldn't be a bad idea, extra thick and tacky and is claimed to be water proof.

Either way, the old bearings look bad, with the shape they are in, i'd check your diff fluid atleast to make sure it don't have water. Either pull the drain plug and see if water comes out, or spin it over some by hand to mix it up well and check the fill cap and see if it looks milky.

Yeah.... I drained the diff oil and replaced it last summer. Didn't look to bad but smelled like hell. The boot is in decent shape too. I heard the boot from the 2005 500 Foreman can be used to replace this one. This one is good though. I can tell getting that swing arm back in is going to be a nightmare.

[ps2fixer]

Yeah.... I drained the diff oil and replaced it last summer. Didn't look to bad but smelled like hell. The boot is in decent shape too. I heard the boot from the 2005 500 Foreman can be used to replace this one. This one is good though. I can tell getting that swing arm back in is going to be a nightmare.

Agreed lol. I couldn't get the one together I was working on w\o taking the diff out, but maybe you will have different luck.

The tip on the trx500 is good, any idea the exact part number or year/model of the trx500? I suspect just about all of the shaft drive hondas with a similar swing arm setup would use the same boot.

[BigRedGrizzly]

Agreed lol. I couldn't get the one together I was working on w\o taking the diff out, but maybe you will have different luck.

The tip on the trx500 is good, any idea the exact part number or year/model of the trx500? I suspect just about all of the shaft drive hondas with a similar swing arm setup would use the same boot.

http://uploads.tapatalk-cdn.com/20160228/62c095be2e56cab5d7dcb780af00b0f1.jpg

[ps2fixer]

Good info :). I looked it up on partzilla and looks like a million machines used it, mainly 1995-2003 trx400 and 2001-2014 trx500 models. Reason I asked is because typically every few years or so honda changes the part number.

http://www.partzilla.com/parts/detail/honda/HP-52101-HM7-000.html

Based on the clamp sizes, looks like this could be a possible match too.

http://www.partzilla.com/parts/detail/honda/HP-52101-HN0-A00.html

First option is about 1/2 the price though, so I'd try that trailprotrailpro the other =).

I might buy both some time (i'm noting them down).

Also side note... the 250sx boot is still in production, but it is a bit more. I'd think the drive shaft tube would be the same size though.

http://www.partzilla.com/parts/detail/honda/HP-52101-HA8-680.html

[BigRedGrizzly]

Got the new bearings in this morning. Not to bad. Put the outer races in the freezer over night and heated the bearing holder with a map gas torch for a bit. They practically dropped in. Had to beat them a bit but just barely. Now I'll be painting the swing arm and getting it attached.
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[BigRedGrizzly]

All back together. That floor jack was key when it came to getting that drive shaft hooked back up. I really needed to jack up the swing arm high. Basically level. Then my 7 year old son helped me by getting the left side in first. The we swung the swing arm to the right which afforded us just a little bit more room so I could push the driveshaft back on the spring. Had to slightly manipulate the axle to get the splines lined up. When it lined up it snap right back. With a little shake of the swing arm it set all the way to the collar. Then moved around the other side and put he pivot bolt in. Lubed the hell out of everything.
http://uploads.tapatalk-cdn.com/20160228/0e7013de7c77fe5170a73d62a7dbe872.jpg
Then it was just a matter of hooking up brake cables and vent lines. Good to go. Very manageable.
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[ps2fixer]

Nice work, I spy a 250es in the background too =).

I noticed the new brake adjuster, half wondering if it came from ebay, if it did it was probably from me.

[Chopsaw]

Next thing you need to do is see if the front tire is rubbing the lower tubes . It may not be touching when standing still, but it looks awful wide . To wide a tire will rub all the way thru the tubes over time . Just FYI

Chop

[BigRedGrizzly]

Next thing you need to do is see if the front tire is rubbing the lower tubes . It may not be touching when standing still, but it looks awful wide . To wide a tire will rub all the way thru the tubes over time . Just FYI

Chop

Hey Chop.....Checked out that clearance. It's tight but it doesn't appear to be rubbing. I'd like to put a narrower tire on there eventually.
Any suggestions?
http://uploads.tapatalk-cdn.com/20160308/b11c73eefbf4d6ae587bec9db256ffe8.jpg

[Chopsaw]

That tire is to wide , and it is rubbing when you ride . I have a thread on the subject with pics , and there is a thread on a tire wheel swap using the stock front end .
http://www.3wheelerworld.com/showthread.php/164830-Front-tire-question-250-SX?highlight=sx+front+tire

Check this out . Then look for the post on wheel tire swap . I have pics in this post that tell the story .

[BigRedGrizzly]

Just ordered the rim 10x5 and a 22X7-10 from partzilla.

[BigRedGrizzly]

That tire is to wide , and it is rubbing when you ride . I have a thread on the subject with pics , and there is a thread on a tire wheel swap using the stock front end .
http://www.3wheelerworld.com/showthread.php/164830-Front-tire-question-250-SX?highlight=sx+front+tire

Check this out . Then look for the post on wheel tire swap . I have pics in this post that tell the story .

Hey Chop... Thanks for the motivation. Got the new tire and rim on... [emoji1303]
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[Chopsaw]

Looks good .

[UPNATM]

Huge improvement! Looks good.