2000 Conquest 8x8, Need some advice..

[Dan67]

im having the exact same issue dan67.gonna let it soak in pb blaster for a day,then go at it with 2 BFH'S.man i cant imagine doing all that work without the upper tub and power pack removed.

Well if you think about it, I imagine it would even be a bigger pain in the butt to separate the tubs and pull the engine. I have several members encouraging me along so that really helps too.. All agree its a huge pain but actually easier the way I am doing it.

Got all the stuff on the right front disassembled and now I'm cleaning the crap up. I did have to put my idler shaft on the shop press and force off the bearing. It was soaking over night and still was a beast to push off, fought all the way. Ended up bending the crap out of a flange. I'll order another 1 tomorrow and hope I can get it fast. Busco is just around the corner.

[Dan67]

Just about ready to take the Conquest on a shakedown ride. Battery is on the charger. I will stick it back in and fire up the Kaw

Lets see, I got the left idler changed out in in under an hour yesterday! Much better then the 5 hours I spent on the right idler shaft. Got the left front axle done up. All bearings are new in it.

Just finished re-chaining the entire beast with new chain. I removed and cleaned all the chain adjusters. While doing that I discovered a broken weld on the bar under the right middle chain adjuster.

I think it will be OK for now but I know I'll need to get that fixed right after Busco, I just don't have time to do a complete take down to remove the frame and weld it up. I think it might be possible to fix with the frame in. Pry that tab up and weld it back. Just remove the chains and the chain adjuster, maybe the axle to be on the safe side.

[plott hound]

cant wait to hear how ya make out dan.lets see some more pictures.

Just about ready to take the Conquest on a shakedown ride. Battery is on the charger. I will stick it back in and fire up the Kaw

Lets see, I got the left idler changed out in in under an hour yesterday! Much better then the 5 hours I spent on the right idler shaft. Got the left front axle done up. All bearings are new in it.

Just finished re-chaining the entire beast with new chain. I removed and cleaned all the chain adjusters. While doing that I discovered a broken weld on the bar under the right middle chain adjuster.

I think it will be OK for now but I know I'll need to get that fixed right after Busco, I just don't have time to do a complete take down to remove the frame and weld it up. I think it might be possible to fix with the frame in. Pry that tab up and weld it back. Just remove the chains and the chain adjuster, maybe the axle to be on the safe side.

[Dan67]

Now I am stuck a bit. I'm looking for a pink wire off the fuse box on the left from looking inside the engine cowl. I see an empty fuse and no wire coming out of the empty slot that I see on the wiring diagram from my online parts manual. It clearly shows where it should be, but its not there. Think tomorrow AM I will see if I can add a terminal to the fuse box, otherwise I'll just have no choice but to wire from the battery. Running out of time fast.

[Bazooo guy]

What are you connecting to the pink wire?
It may have been omitted at the factory if it was for an optional acc.
If you connect to the battery install an inline fuse (correct size) to protect the line.

[plott hound]

i can see if theres a pink wire on mine if you like

[Rock Doctor]

Just finished re-chaining the entire beast with new chain. I removed and cleaned all the chain adjusters. While doing that I discovered a broken weld on the bar under the right middle chain adjuster.

I think it will be OK for now but I know I'll need to get that fixed right after Busco, I just don't have time to do a complete take down to remove the frame and weld it up. I think it might be possible to fix with the frame in. Pry that tab up and weld it back. Just remove the chains and the chain adjuster, maybe the axle to be on the safe side.

I had that happen last fall, and you might want to fix it befor you go for a ride.
On mine, the bar broke right out from under the frame, then the tensioner jumped out of it's bracket, then the chain/sprocket ate the tensioner, which damaged the sprocket teeth.

I ended up welding the bar back in from the top side, be careful welding under the fuel tank

I posted a thread, with pics, but can't find it with this iPhone

RD

[Dan67]

Now after my test ride with Russriders yesterday afternoon, I'm not so sure that weld is broken. It was hard to tell and I assumed it was because the little crossbar is welded a bit lower then the others.. Not really sure what us with it but it held up just fine. Only other news is after a morning of cleaning up the mud and muck, I seem to have demounted 6 of 8 tires from the rims. That's including the tires with tubes, no tube valve stems or any other stems are damaged either. Anyhow, time to reload the conquest and head over to the tire shop and have a good laugh over it.

[Dan67]

Ready for Busco..

[Dan67]

The hinge on the windshield is splitting apart on the ends. Does anyone know where I can get a replacement hinge for the Conquest?