Drive axle removal 1980 Invader 440

[dirtbag]

Last year I bought this sled and it was a blast to be riding again. What a hoot! Pull the trigger and hang on!

During the summer I removed the suspension, freed up all the seized bits, got a new shock, cleaned and and painted and then added new sliders. Then I decided the track was pretty tough and decided to replace it with a used but better one a friend had.

Problem: How do I remove the drive axle? I read through a few manual online and the story changes slightly each time.

I have the chain case opened and the bottom sprocket removed (manuals said to remove both sprockets but I don't see the point) I also have the 3 bearing housing cover bolts removed from the other side. One manual said I need to remove the lock collars on the axle but that sounds like something you do to remove the actual drive sprockets from the shaft.

Also it looks like there is a type of circlip that needs to be removed before the splined end will pass through the lower chain case bearing but when turning the shaft I didn't see a split in this clip and there was no mention of it in the manuals I read.

I thought I'd consult the experts before going much further.

I'm also curious if I should expect grief when trying to remove the bearing housing from the left side - obviously it's tight to get at hiding under the clutch/drivebelt on that side.

All advice greatly appreciated.

[dirtbag]

Ok had another go and things are clearer - didn't hurt getting out the cheaters to aid the aging eyesight.

The circlip turned out to be just a thin washer between bottom sprocket and lower chain case bearing. Removed the left side collar and set screw - right side is currently getting a soaking of liquid wrench. It still looks like these aluminum ring like collar are there to hold the drive sprockets in place more than secure the shaft.

I now have the shaft moving side to side, however the left side bearing, seal and three bolt housing are firmly in place on the left end of the shaft. Not sure how to free them but I'm pretty sure removing the shaft from the housing/bearing assembly is key.

I thought maybe I needed more movement on the chain case side. I removed the large circlip retaining the lower bearing but it is still firmly in place in it's bore.

Again if anyone with insight can chime it would be greatly appreciated.

[mswyka]

The bearing cap on the non-splined end of the shaft should just slide off the bearing.  There is a rubber "O" ring inside the cap to hold the bearing tight to the cap.  Old grease and corrosion are probably keeping the cap there.  If you have the chain and the gears off the shaft and the cap off the bearing the shaft should just slide out.

[kawhead]

tip the sled on the left side, make sure the track is off the drivers. put a 2x4 between the plastic teeth,tap shaft out of chaincase, it will then tip and let you replace the track.....may have to do more than tap

[dirtbag]

Okay finally got it off. After having trouble freeing the bearing from the bearing housing with three bolts  I came up with a good idea. Using a longer bolt that threads into the end of the shaft (on the sprocket side) some thick washers for adjustment and a 1 1/4 socket I created a puller. Then I cut out a 1/2 inch plywood donut and cut it in half. This acted as a spacer between the housing and the tunnel. After tightening the "puller" the bearing moved somewhat then I took the spacer and doubled them to take up more space and tightened the bolt again. The bearing popped right out.