2000 Conquest 8x8, Need some advice..

[Dan67]

Hey guys,

With the warmer weather today I started to mess around with my new to me Conquest. I siphoned out the old skunk gas, replaced it with 2 gals of super unleaded with fuel stabilizer mixed in. I might add some ATF to it later.. I went ahead and made 2 new windshield snap hold downs. Pulled out the floor pans and the firewall to get it ready to change the gear lube and engine oil tomorrow. Checked the brake pads, I'll need to replace them soon, but not right now. Checked the belt and belt tension, belt looks good but the tension??? I dunno feels like I can push down on it more then 1.5" with my thumb. I know I need to replace all the chains, I got 20' of new Diamond 50-2, waiting on the rest of my connectors to arrive in the mail. I have never used a chain tool, just hit the end piece with a grinder and punch out the pins. I guess I should get the proper tool.. Still need to find a good deal on the 60-1 rear chains.

While I was looking around inside with the trouble light.. I seen some trouble.. looks like all the outer bearings are shot.. I see grass wrapped around the axles from the inside of some of the outer bearings. I think these might be the original bearings. On both idler shafts the outer flanges are missing the top nuts and flanges look to be bent. How hard is it to replace the idler flanges and bearings? I assume I'll need to take the battery out to gain access to the right side?

I got a rear seat kit and I need instructions on how to assemble it. I can figure out some of it.. but the 8 sealed rivets?? Not sure on how it mounts to the frame.

[Frymechanic]

Not exactly sure how hard the bearings will be but there are manuals in the manuals section that should help you with the breakdown process. As for the belt tension, you don't want to tighten it too much because its a CVT drive and its supposed to be loose while engine is off or idling as this creates the neutral effect for stopping. It tightens itself as it accelerates. Good luck!

[Dan67]

Chain Tensioners

I have been trying for the last hour to take the tension off the tensioner so I can replace the chain with new. How the heck does it come loose, it is at the max setting. I was looking at the rear tensioners and noticed they where actually stuck open and did not apply any tension to the 60 chain.

[Dan67]

Called Lewis and he was able to help me out. I was able to remove the bad flange, shredded bearing, and seized inner bearing. Time to get it assembled next.

[lewis]

Glad to help Dan.

[Dan67]

Just a bit of an update to my conquest.. I have replaced the inner and outer bearings, seals, gaskets, bolts, washers, lock-nuts, & grease zergs on all the axles except the 2 tires in the front and the idler shaft. I got the battery and tray out last night. I am planning on removing the last of the chain off the front axles tonight and remove the idler shafts and start cleaning them. I hope to get the front axles removed and cleaned this weekend. I can already foresee reassembly to be a major pain in the butt solo.. I hope I can get another pair of hands to help me put it together. There is not much of any room in the front around the engine/tranny and frame.

[Slimpickin]

Pick up a pair of needle nose vice grips for reinstaling the chain. Grind a small indent in each jaw of the pliers. You can then grab the chain and pull both ends together
and install the connector quite easily. It's easy to turn the screw in the handle to loosen or tighten the chain to make the connection easy. I keep them under the seat in the argo
so they are easy to find.

Slim

[Dan67]

I got lucky on getting the chains off, the master links where very close so I did not have to roll the conquest much to get to them. But I did discover that the right side idler shaft bearings are shot. I already have those just in case. Man talk about a huge pain to remove.. I'm sure its even gonna be a bigger pain in the ass to put back in. I am having a hard time with the right front axle. That SOB will just not come off the inner bearing. There is no room on the inside to use my gear/bearing puller. Looks like I might have to go and get a slide hammer to try to get this sucker out.

[Dan67]

Picked up a slide hammer today and just took 6 pulls on the slide hammer and it popped right out! The local Advanced Auto Parts wanted to rent me a hammer at $135 a day.. Bought 1 at Northern Tool for $75 instead. Just sucks I had to spend 2 hours driving out to get it. Now to get those dirty pigs cleaned and reassembled.

[plott hound]

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.

I got lucky on getting the chains off, the master links where very close so I did not have to roll the conquest much to get to them. But I did discover that the right side idler shaft bearings are shot. I already have those just in case. Man talk about a huge pain to remove.. I'm sure its even gonna be a bigger pain in the ass to put back in. I am having a hard time with the right front axle. That SOB will just not come off the inner bearing. There is no room on the inside to use my gear/bearing puller. Looks like I might have to go and get a slide hammer to try to get this sucker out.

[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.