Wednesday, February 22, 2017

Dirt Bike Fork/Dust Seal Replacement



*As always, these instructions are general guides to helping you; always check with your service manual for your machine to make sure that you have a clear understanding of the setup. If you are not experienced with installing parts on your machine, Boss Bearing always recommends taking your machine to a mechanic to ensure proper installation. You can buy the partsthrough us, save a few bucks, and take them to your local mechanic to be installed!

Instructions:


*It is important to make sure you clean your machine to prevent any problems going forward with the installation.

*Please be sure to follow the instructions thoroughly! If the steps to replacing any parts on your dirt bike are done improperly, this can lead to parts failure or possible injury.

Steps:


1. Place the dirt bike on a stand getting the front wheel off the ground. Remove the front wheel and hang caliper so no damage will occur to the brake line hose.

2. It may be necessary to remove the handle bars. Loosen the top cap of the fork (usually 46mm-50mm fork cap wrench will be best to use). It’s best to loosen it while the forks are still on the bike.

3.  Loosen the triple clamp bolts holding the fork legs in place. Remove the forks from the bike.

4.  Remove the top cap and compression adjustment rod and spring. Drain the old fluid from the fork.

5.  Remove the dust seal with a flat screw driver. Then remove the retaining ring clip to allow the fork tube to be disassembled. Separate the fork inner and outer tube by jerking them in opposite direction of each other.

6.  After the fork is separated, you can now remove the bushings, washers, and inner oil seal (keep the parts organized). Clean and inspect all parts for wear and tear. (Replace any parts that are damaged)

7.  Using a seal bullet or, if you don’t have one, use tape on the sharp edges of the fork to prevent the new seal lips from tearing. Slide the new seals, clip, washers, and bushings back on the fork tube in the same pattern they were removed.

8. Reassemble the fork tube and using the proper fork “seal driver” (needed and required), drive the new seal in place. Put the retaining clip back in place, then drive the dust wiper seal.

9. Drip the fork spring into the fork then fill it with the proper amount of appropriate fork oil.

10. Reinstall the compression adjustment tube and the fork cap.

11. Compress the fork leg many times to circulate the fluid.

12. Reinstall the forks back on the bike and reassemble it.


Now you are all set to get back out there and ride again!





Wednesday, December 7, 2016

Dirt Bike Engine Oil Seal Replacement Guide



*As always, these instructions are general guides to helping you; always check with your service manual for your machine to make sure that you have a clear understanding of the setup. If you are not experienced with installing parts on your machine, Boss Bearing always recommends taking your machine to a mechanic to ensure proper installation. You can buy the parts through us, save a few bucks, and take them to your local mechanic to be installed!

Instructions:
*It is important to make sure you clean your machine to prevent any problems going forward with the installation.

*Please be sure to follow the instructions thoroughly! If the steps to replacing any parts on your dirt bike are done improperly, this can lead to parts failure or possible injury.


Steps:

1. Remove the most difficult seals first; the main crank seals. The flywheel and electrical stator must be removed by using a special flywheel puller tool.
To remove the old seal, use a seal puller or flat pick to pull it from the case
Compare old seals with new seals for size accuracy. Install the new one with a seal driver tube until it’s flush with the engine case. 
Reinstall the flywheel and stator.
2. Clutch side seal must be replaced by removing the right engine clutch cover case, along with the clutch basket and primary drive gear.
Remove old seal and compare to new for size accuracy
Install new seal and reassemble the clutch side
3. Clutch arm seals usually are held in by a retaining bolt or snap ring.
Remove the clutch arm actuator to remove and install the new seal
4. The kicker shaft seal must be removed by unbolting the kick starter lever from the shaft.
Remove the old seal and compare it with the new seal, then install it and reinstall the kicker
5. The shifter lever must be removed to replace the shift shaft seal. 
Remove the pinch bolt that’s holding the shifter on. Then remove the shifter and old seal. Install the new seal and the reinstall the shifter.
6. Remove the front sprocket by using the chain and rear brakes to assist with loosening the sprocket/counter shaft nut
Remove the sprocket and any seal guard/shield to get to the old seal. Pull the seal collar from the shaft, then remove the old seal and compare it to the new seal.
Install the new seal and inner seal collar
Reassemble and torque it to OEM specifications 

Thursday, November 3, 2016

Motorcycle / Dirt Bike (or Sport Quad) Swingarm Bearings and Seals Installation Guide




*As always, these instructions are general guides to helping you; always check with your service manual for your machine to make sure that you have a clear understanding of the setup. If you are not experienced with installing parts on your machine, Boss Bearing always recommends taking your machine to a mechanic to ensure proper installation. You can buy the bearings through us, save a few bucks, and take them to your local mechanic to be installed!

Instructions:

*It is important to make sure you clean your machine to prevent any problems going forward with the installation.
*Please be sure to follow the instructions thoroughly! If the steps to replacing any parts on your motorcycle or ATV/UTV are done improperly, this can lead to parts failure or possible injury.

Steps:

1. Before you begin this process, uninstall the original swingarm and linkage from your motorcycle or ATV.

2. Remove the rear wheel/wheels (ATV) by removing the bolt or lug nuts along the axle.

3. You can now unbolt the caliper from the swingarm, making sure to support it from causing damage to the caliper or brake lines.

4. Remove shock and linkage being sure to inspect the bearings and seals in these points. Replace them if needed.

5. Clean the swingarm thoroughly. After you clean them, remove the original seals, bushings, and pins, using necessary needle bearing and seal removal tools. You’ll want to clean all the rust out the bearing bores as well.

6. After the bearing bore has been cleaned, check it over for any wear and tear damage. Install the new bearings.  Put them in rounded end first and press on them from the outside, pressing on the number and letter side of the bearing. Once they are pressed in, grease the new bearings and grease the lips of the new seals.

7. Install the new seals, bushings, and pins to proper manufacturer specifications. If you know your motorcycle has thrust bearings, place the PTFE washer that comes in the kit inbetween the steel washers. The PTFE washer surface should be facing the outside of your bike.

8. Reinstall the swingarm now. We recommend putting grease or antiseize on the swingarm bolt for easier future maintenance. Torque the nuts/bolts to OEM specifications.

9. Now you can reinstall the linkage and rear shock and break caliper and axle/wheel(s). Check the chain adjustment before tightening all nuts and bolts to specs.

Now you’re ready to get back out there and start riding again!

Thursday, October 13, 2016

UTILITY ATV SWINGARM BEARINGS INSTALLATION GUIDE





*As always, these instructions are general guides to helping you; always check with your service manual for your particular machine to make sure that you have a clear understanding of the setup. If you are not experienced with installing parts on your machine, Boss Bearing always recommends taking your machine to a mechanic to ensure proper installation. You can buy the bearings through us, save a few bucks, and take them to your local mechanic to be installed!

Instructions:
*It is important to make sure you clean your machine to prevent any problems going forward with the installation.
*Please be sure to follow the instructions thoroughly! If the steps to replacing any parts on your ATV/UTV are done improperly, this can lead to parts failure or possible injury.

Before you Start:
Before you start to remove your old swingarm out of your ATV, organize the new kit in a way that will make it easier for you to install them. Once you do that, you can remove the pivot caps on the swingarm. It’s important to make sure you are supporting the bottom of the frame so all the weight isn’t on the swingarm. 

Steps:
1.  Remove the rear axle and final drive unit so you can take the swingarm from the lower shock mount. Take a lock nut wrench and take out the pivot lock nut with it. 
2.  Now you can remove the swingarm by taking out the pivot bolts and drive shaft joint boot. After that’s out, remove the dust seals. Use a proper bearing puller and pull out the bearings. After the bearings are out, you can remove the bearing grease holder now. 
3.  Before moving on, be sure to thoroughly clean the old grease and grim and any rust buildup from the bearing bores. Then you’ll want to make sure there isn’t any damage done to the bore. If there is, this could cause problems with installing the new bearings. 
4.  Once you’ve inspected the bearing bore, you can now put the new grease holder in place. Find the bearing race out of your new kit and install that. When you drive the bearing race in, it’s very important to make sure you use a proper driver that will only come in contact with the outside race. 
5.  Next you’ll want to grease the new bearing and install the bearing into the races. You can now press in the grease seals that will also hold the bearing in the race. Then put some grease on the lips of the dust seal and install it into the swingarm. 
6.  Now it’s time to reinstall the swingarm on the ATV. So, install the pivot bolts, caps, rear axle and final drive unit. First apply a thin coat of grease to the swingarm pivot bolts and install the swingarm to the frame. Then, tighten the bolts to OEM specification. Now tighten the locknut to OEM standards with the locknut wrench you used to remove them. 
7.  Now you can install the pivot caps. Once that’s done you are now ready to tighten the fasteners to OEM standards. 

Wednesday, September 7, 2016

Repair Shop Discount Program

 Boss Bearing Repair Shop Discount Program



Toll-Free: 1-888-400-BOSS (2677) • 2100 W Front St. Statesville, NC 28677

Do you fix dirt bikes, motorcycles, ATV's, UTV's or snowmobiles ? Do you have your own repair shop?

Boss Bearing offers special volume discounts for repair shops. Qualified program participants can enjoy the quality products that we sell at a lower cost. With different levels, Boss Bearing is offering these discounts to small repair shops, as well as, larger establishments.

Here's how it works:

1. Fill out the Repair Shop Discount Program application 
2. Once we review your application (please allow 1-3 business days) we will contact you with our discount codes;

3. Discounts are tiered based on your order size. Orders between $49.99-$99.99 qualify for an additional 10% off our already low sale prices, orders between $100.00-$299.99 qualify for an additional 20% off our already low sale prices; and all orders over $300.00 qualify for an additional 25% off our already low sale prices.

Friday, August 12, 2016

Installation Guide for Replacing a Differential Bearing Kit



*As always, these instructions are general guides to helping you; always check with your service manual for your particular machine to make sure that you have a clear understanding of the setup. If you are not experienced with installing parts on your machine, Boss Bearing always recommends taking your machine to a mechanic to ensure proper installation. You can buy the bearings through us, save a few bucks, and take them to your local mechanic to be installed!

Before you Start:

*It is important to make sure you clean your machine to prevent any problems going forward with the installation.
*Please be sure to follow the instructions thoroughly! If the steps to replacing any parts on your ATV/UTV are done improperly, this can lead to parts failure or possible injury.
*Once you take the new parts are out of the packaging, place the bearings in the freezer for around one hour; this will allow the bearings to contract to a smaller tolerance.

Remove The Old Bearings:

1.  Drain all of the oil out from the differential and then remove the actual differential from the frame. 
2.  Loosen the differential case bolts evenly and remove them. Next, remove the case cover by finding and using the pry points.
3.  Remove the old bearings and seals out from the differential housing. Match up the seals from the new kit with the old seals that you pulled out.  Please note:  there may be extra seals because most of these kits are designed to fit multiple machines.
4.  Now you will want to remove the ring gear bearings. Once you remove this, inspect the bearings for any wear and tear. Then use a seal pick or any type of flat blade to remove the oil seals. 
5.  Next, drive the old bearings out from the differential case. You will want to clean the bearing bore and make sure it is free of any grease or rust. Inspect it closely for any wear and tear. This is important to do so that the new bearings do not hang during the installation.
6. Remove the pinon gear seal using a pick. Next you will remove the inner lock nut.  A special lock nut tool is usually used for the gear shafts that are held in place by an inner lock nut. Be careful not to damage the case or threads while you drill out the stake in the inner lock nut. Now use a special lock nut wrench to loosen up the inner lock nut. Remove the pinon gear next. You can use a special puller tool for this. Remove the bearing from the pinon gear shaft. 

Installing The New Bearings:

1.  Use a bearing driver to install the shim and bearing into the pinion shaft. 
2.  Follow the OEM instructions to remove the needle bearing retaining ring.
3.  Next, use a bearing puller to remove the needle bearing. If the needle bearing is still in the freezer, remove it and install the retainer ring onto it. Now try and fit the needle bearing and ring into a compressor tool (common for Hondas). 
4.  Use the heat gun to heat up the case and then drive the bearing into the heated case. Use one solid strike if the bearing uses a retaining ring.
5.  Now you will want to make sure the bearing is fully seated in the case. If it uses a retaining ring, make sure it is seated fully in the groove. 
6.  Next, install the pinion into the case. Drive it into the case with a driver that contacts the outer race of the bearing.
7.  Now you can install the gear shaft inner lock nut. Tighten it to your OEM specification with the wrench. Without damaging the threads or the case, strike the inner lock nut with a hammer. 
8.  Apply grease to the new pinion oil seal and install it so it is fully seated on the bearing. 
9.  Place the ring gear with the correct shims. If this gives you any backlash, you should get it inspected to be sure everything is set correctly. 
10.  Using a heat gun, heat up the bearing bore and install the bearing that was in the freezer. Drive the bearing into its correct place using a bearing driver that matches the outer race and make sure it is fully seated in the bore.
11.  Now, depending on the type, install the cover with the O-ring, sealant, or gasket. Put the case bolts in and tighten them evenly to the OEM specific torque. 
12.  Now you are ready to install the differential back to the frame/swingarm, and put the machine back together. 
13.  Lastly, fill the final drive oil, and you are done!

Monday, May 9, 2016

Dirt Bike Installation Guide for Replacing Rear Wheel Bearings


*As always, these instructions are general guides to helping you; always check with your service manual for your particular machine to make sure that you have a clear understanding of the setup. If you are not experienced with installing parts on your machine, Boss Bearing always recommends taking your machine to a mechanic to ensure proper installation. You can buy the bearings through us, save a few bucks, and take them to your local mechanic to be installed!

Before You Start:

It is important to make sure you clean your machine to prevent any problems going forward with the installation.

Please be sure to follow the instructions thoroughly! If the steps to replacing the rear wheel bearing on your Dirt Bike are done improperly, this can lead to parts failure or possible injury.

Before you get started, make sure you prop up your bike on a stand to lift the wheels off of the ground.

Once it is lifted, you can begin to remove the rear wheel on your bike. To do that, unscrew and remove the axle nut, and remove axle bolt, then remove the chain off the rear sprocket, then remove the wheel.
*Note: be sure to watch for any seal spacers or washers that could fall out. Take the wheel you just removed and prop it up on a box, stand, or table so it is easier for you to work on.


Remove the Old Bearing:

Now remove the seals so you can see the actual bearing. You can remove the seals simply by using a screwdriver or pick. *Note: some wheels require specialty tools for the bearings to removed, reference your service manual or local dealer for tools and techniques before moving on.

To remove the bearing, use center punch and hammer to drive the opposing side bearing out using side to side tapping. Do the same thing to the other side. Try to avoid damaging the center spacer tube.

Install the New Bearing:

Clean the wheel thoroughly. Press the new bearings in by the outer race using a bearing driver. If there isn’t already grease on the bearings, go ahead and smear some on them. Be sure to replace the center spacer tube before installing the bearing on the other side. Now press your seals in and put the seal collars in place.

Now you can reinstall the wheel on the bike. Be sure to check for equal chain adjusting spacing, and you are good to go!