Clearance issue between brake rotor bolts and chain case carriage bolt heads! - Snowmobile Forum: Your #1 Snowmobile Forum

Mr. Hart · 11-03-2009, 03:14 PM

Currently, I am rebuilding a 2002 ZR 800 EFI. I have changed out the track and rebuilt the skid frame. I am to the point of reassembly of the chain case. The problem is that now, the brake rotor mounting bolts are interfering with the carriage mounting bolt heads on the chain case! Where did I go wrong? The jack shaft has not slid over (clutches are still aligned with the same shims as before), but there is most definately a clearance issue. Any suggetions or ideas would be more than just appreciated. Thank you.

**RJ Gleason** · 11-03-2009, 03:57 PM

Bolts going in from the wrong side, maybe?
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JheLrey · 11-03-2009, 03:59 PM

Bolt heads are usually on the inside of the tunnel????

Mr. Hart · 11-03-2009, 04:06 PM

Thank you for the ideas. However, I have looked at my shop manuals and diagrams, and I am fairly confident that the bolts are all located in the correct position. I don't see that there were any shims behind the chain case, but I am wrong? The distance that I will need to gain is about the thinckness of a washer. There has to be something that I am overlooking, and usually, that something is very obvious and simple. Again, thanks for the input, but are there any other ideas or thoughts?

JheLrey · 11-03-2009, 06:40 PM

Bearing flanges from the inside to the outside could change it enough.... Did you pull the chaincase completely to remove the track?

Mr. Hart · 11-03-2009, 07:26 PM

Yes. I did remove the entire chain case. What do you mean by the bearing flange on the outside. The three carriage bolts that hold the flange onto the chain case come for the back side of the chain case, and the bearing flange is inside the chaincase. This presses the oil seal against the chain case wall to prevent leaks. I am pretty sure that there is no bearing flange on the outside of the chain case or am I misunderstanding you all together. As I said earlier, it has to be something obvious (and probably will be so obvious that it is embarrising) that I am overlooking. Thanks for the help.

JheLrey · 11-03-2009, 08:07 PM

I could see the shaft being put back in where it would change spacing. Any missing washers?

**kccats** · 11-04-2009, 09:53 AM

Did you have the rotor off? It is supossed to slide back and forth on the splines!

Mr. Hart · 11-05-2009, 06:37 PM

I have not pulled the brake rotor. I will look at this again. Thank you for all of the advise.