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Unread 06-23-2011, 02:19 PM   #41
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Default Re: Increase hill and overall speed 2000.5 series

Nice thread.........good info.
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Unread 06-23-2011, 02:22 PM   #42
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Default Re: Increase hill and overall speed 2000.5 series

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Unread 06-29-2011, 01:50 AM   #43
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Default Re: Increase hill and overall speed 2000.5 series

Got her down to the bones tonight to install the new motor (different thread discussion on that), HD springs and some general clean up (e.g., might as well change the diff fluid while I'm in there) and found the left rear frame weld is broken - see pic compared to OK weld on the other side. I think only issue is the rear most bar to which I need to connect my rear seat will be an issue. Any thoughts on problems this may raise and solutions? Obviously I could re-weld (really dont want to do this) or somehow connect with a u bar or something creative but looking for expert opinions. Thanks.
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File Type: jpg normal frame right rear.jpg (80.8 KB, 12 views)
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Unread 06-29-2011, 06:59 AM   #44
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Default Re: Increase hill and overall speed 2000.5 series

It looks like there is sufficient room to drill a thru hole and bolt it together using maybe a 3/8" stainless nut/bolt with washers for added strength . . . or same size bolt grade 5 zinc plated . . .
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Unread 06-29-2011, 08:11 AM   #45
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Default Re: Increase hill and overall speed 2000.5 series

Yep? Put 2 bolts in there and space them out equally
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Unread 06-29-2011, 10:40 AM   #46
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Default Re: Increase hill and overall speed 2000.5 series

Cool - was hoping a relatively simple solution like that was what the doctor ordered - thanks, guys.
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Unread 06-30-2011, 12:02 AM   #47
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Default Re: Increase hill and overall speed 2000.5 series

Good news tonight - took the 4 bolts out of the motor and it slid right off with a few wiggles - big thanks to the guy out there that put it on with anti-seize wherever you are and thanks to this forum for the help so far!

Now, I have a few questions for the experts before installing the new motor:

1) What's the best way to clean the gunk inside there (see first pic)? I've brushed and vacuumed out most of the stuff but probably need a solvent or similar at this point.
2) What are the pieces on the spline in the first pic? Looks like a spring of some sort (what's the purpose?) and are the two outermost pieces the guide ring?
3) Are the pieces on there in the correct order? I was a bit careless and pulled the guide ring pieces off only to drop them...
4) Second pic shows a close up of the two pieces that I assume make up the guide ring - do they look ok to re-use or should I replace? If I re-use, what's the best way to clean them?
5) Third pic shows similar views of the stock motor (left) and a new D392 motor (right). I see a bracket on the old stock motor not on the new motor - should I knock the bracket off the old motor to use on the new one? If so, just bang it or ? because it is definitely not moving from a few rubber mallet taps so far...

Thanks!
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File Type: jpg Spline and guide ring.jpg (137.3 KB, 13 views)
File Type: jpg Guide ring.jpg (139.0 KB, 9 views)
File Type: jpg old & new motor.jpg (175.5 KB, 13 views)
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Unread 07-01-2011, 10:14 PM   #48
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Default Re: Increase hill and overall speed 2000.5 series

Finally got around to the sport windshield. Next the roll bars then the disc brakes. It was only a few months ago this thing wasn't even running
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File Type: jpg blackwwindshield.JPG (339.4 KB, 8 views)
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Unread 07-01-2011, 10:16 PM   #49
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Default Re: Increase hill and overall speed 2000.5 series

..............i likkkkkkkkkkkkkeit..........................
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Unread 07-01-2011, 10:23 PM   #50
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Default Re: Increase hill and overall speed 2000.5 series

Thanks Tom I was looking at kellerjams blue & chrome and going hmmm but man I like the black. Thanks again for all of your help back when I was trouble shooting the heck out that thing
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