Outer Cush Drive Assembly

[TURBO200R4]

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​

i have seen a lot of bolts/nuts overtighten must of the time it stretches the thread and locks down the nut/bolt so you break the stud/bolt trying to take it off.
most likely left them loose or put them on backwards if nuts.

 

[mikevujcich]

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.

The large torx screw is your starting point. After that I'm not much help.
Possible the nuts were tightened to 70 fp instead of 70 nm ?
The whole rear drive comes off easily, lift brake off and hang, take off light bar and hang, remove abs sensor. Take off the 4 cap screws and your on the bench

 

[mikevujcich]

The large torx screw is your starting point. After that I'm not much help.
Possible the nuts were tightened to 70 fp instead of 70 nm ?
The whole rear drive comes off easily, lift brake off and hang, take off light bar and hang, remove abs sensor. Take off the 4 cap screws and your on the bench

Oops, it is 100 Nm with 25 first.