Outer Cush Drive Assembly

[Maldayven]

Has anyone had to take apart or replace their outer cush drive assembly, and if so, does the large stem going through the whole assembly unscrew with the torx bit from the outside, or the large wrench from the inside?

All 5 of my studs snapped in half yesterday while riding, luckily the wheel kept in the wheel well and I was going slow enough to stop, so I did not crash, but if warranty doesn't cover this (purchased 2 years ago), then ill have to replace it myself.

The diagram shows it taken apart, but not really instructions on how it comes apart.

 

[papanorm]

This doesn't make sense to me, what am I missing? Had you overtightened the lug nuts by double the torque?

 

[Maldayven]

This doesn't make sense to me, what am I missing? Had you overtightened the lug nuts by double the torque?

Im not really sure how they snapped, wheel had been replaced about 3 weeks ago. Could have been overtighten, not tightened enough allowing free play, and some other excuses I was given.

 

[papanorm]

I am glad you were not injured when this happened. My perception is the mechanic that replaced your wheel is at fault and needs to repair your bike.

 

[Maldayven]

I am glad you were not injured when this happened. My perception is the mechanic that replaced your wheel is at fault and needs to repair your bike.

Couple of my buddies are saying its cause its got too much **** torque, wheel couldn't keep up lol.

 

[atomsplitter]

According to my manual the cush drive removal starts on page 1251. It appears you need the cush drive outer assembly replaced part #T2010783. Hermy's lists the price of that unit at $476.35
Remove the four bolts and that assembly comes off.

Since you have the rear wheel off here is the pertinent parts from my manual:

5. Release the fixings and remove the cush drive outer. Discard the fixings. (From your photo that's the 4 bolts at the back you can see)

If you want to go further, here are the steps:
Note
• Note there is a snap ring that secures the splines of the cush drive to the splinesof the bevel box.
• Note the orientation of the cush drive rubber for installation.
• Note the position of the conical washer for installation.
• Note that there are five dowels on the bearing housing for installation.
6. Remove the cush drive rubber.
7. Pull the cush drive inner out from the bevel box.
8. Collect the conical washer from the cush drive.
9. Release the fixings and remove the bearing retaining plate. Discard the fixings.
10. Taking care not to damage the pulser ring and bearing housing, use a rubber faced mallet to gradually and evenly remove the bearing housing assembly.

 

[Kevin frazier]

Whoever changed that tire mucked up. If i had to rely on someone to wrench on my bike i wouldnt ride anymore. This could’ve been a horrible story. Im glad you survived this.

 

[Kevin frazier]

Couple of my buddies are saying its cause its got too much **** torque, wheel couldn't keep up lol.

Funny but noooo

 

[atomsplitter]

The studs that are now gone were installed to 57Nm part# T2012154, and the nuts are torqued to 100 Nm in two passes, first pass to 25Nm and second pass to 100. Who ever did the final torque must have used a pneumatic impact wrench to shear those threads. The stud size is listed below.

M12 x 1.25 x 56.5​

 

[TURBO200R4]

looking at the destruction i would say that the the rim is most likely bad
look for cracks near the lug nuts/bolts are
check area the the nuts/bolts may be out of round.
the area the centers the rim might be wore out if not to bad you might be able to make a few stake marks so it fits good.
dang mechanics