Does the front clip of the chassis (welded nose assembly) need to come off to get the gearbox out, or
do I need to pull the track adjuster and ball bearins apart using a puller? To this point everything was going smoothly,
even removing the rubbers off of the the bogies, thanks to the pictures that Barrie had provided awhile back.
Thanks,
Jeff
Removal of a 500 gearbox
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1968 - 500 Diablo
1964 - 100D Arctic Cat
1972 - Polaris Starfire (Originally sold by my father)
1975 - Polaris Colt x 2 (Originally sold by my father)
1974 - Polaris Custom (Originally sold by my father)
1964 - 100D Arctic Cat
1972 - Polaris Starfire (Originally sold by my father)
1975 - Polaris Colt x 2 (Originally sold by my father)
1974 - Polaris Custom (Originally sold by my father)
- Go Go Diablo
- Site Admin
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- Location:Sobieski, Wisconsin
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Re: Removal of a 500 gearbox
Hi Jeff,
You sure are making great progress.
From your picture, it looks like the front nose tin is welded to the main chassis. Usually, it's bolted on. Sorry to say, but it looks like you will need to cut the welds to get the nose tin off before the gearbox will come out the front.
When you get your chassis apart, consider giving it some updates like the later model 502/3 has. Reinforce where the bumpers mount, add a "U" channel to the outer edges and add pins on the bogie rail to stop the bogies from flipping over. Also, add some weld to the top side tubing to chassis connections.
Keep up the good work
You sure are making great progress.
From your picture, it looks like the front nose tin is welded to the main chassis. Usually, it's bolted on. Sorry to say, but it looks like you will need to cut the welds to get the nose tin off before the gearbox will come out the front.
When you get your chassis apart, consider giving it some updates like the later model 502/3 has. Reinforce where the bumpers mount, add a "U" channel to the outer edges and add pins on the bogie rail to stop the bogies from flipping over. Also, add some weld to the top side tubing to chassis connections.
Keep up the good work

Too many Diablos and parts to count.
Yamaha 600 SX
Yamaha 600 SX
Re: Removal of a 500 gearbox
Thanks Bruce, I thought I might have to do that, I 'm glad I got the reinforcment brackets from you, I think they'll come in handy.
Jeff
Jeff
1968 - 500 Diablo
1964 - 100D Arctic Cat
1972 - Polaris Starfire (Originally sold by my father)
1975 - Polaris Colt x 2 (Originally sold by my father)
1974 - Polaris Custom (Originally sold by my father)
1964 - 100D Arctic Cat
1972 - Polaris Starfire (Originally sold by my father)
1975 - Polaris Colt x 2 (Originally sold by my father)
1974 - Polaris Custom (Originally sold by my father)