iltrooper

Don't feel bad guys, I'm in west central Illinois and I have the same parts service as you do! So far I've mastered my repairs, but I admit no wiring problems. If the diagrams I have are any good, between my son and I, we should get it!

Mauy Thai, My first axle broke the bearing cage, the second pulled apart from frame breakage on the swing arm mount. Check your play in that swing arm. Hal

http://www.klung-motor.com/accessories-one.asp?news_id=778 Hope this link works!

Well, had a good run yesterday, lots of ditch crossing, climbing, and some good all-out running and all went well! Still have a few little thing to tidy up, but am finally happy with my Trooper. Thanks again guys for the info and support!

OK, it's back together enough to take out and try! So far, so good! Hard left turn under power was how I pulled it apart the last time, so I repeted the move couple times with no problem. I couldn't do any ditch crossing right here without upsetting a neighbor, so will have to wait on that. Lenny, Rocmoc, and Kinarfi, thanks again for all the input. I'll probably drive you nuts with some minor electical questions in the near future! I'll try to figure out how to post the pics of the broken frame soon. I was really surprised that I had NO swing arm breakage. I cleaned all the bushings after finding the steel sleeves froze in them, and installed grease zerks. With the sleeve floating finally, I really tightened the bolts. I had good movement in them without slop. While I was there, I replaced the axle bearing in the hub with taper bearings. I foolishly bought the bushings for the hub mount in the swing arm, but found I didn't need them. If anybody feels the want for them, message me. I re-assembled the axle, leaving the o-ring off of the inner bell. The rest of the job went well.

Thanks Lenny! I just spent the better part of the afternoon looking for parts. No swing arm bushings are available. I also listed a couple more contacts in dealer list, but I don't see them there now. Mine also has 1000 miles on it, unfortunately I've only got to put 100 of those on myself. The cost of being a tight-ass! I feel all can be fixed and hopefully affordable. Hopefully by tomorrow I'll have more info.

I had a master switch problem. I store my T2 in a warehouse so when I was in there I would always start it and let it warm just to know all was well. For no reason one day it wouldn't start. It would roll over only. No spark or injector pulse, (checked with a GM noid) but dash cycled, fan cycled, lights and accessaries worked. Thinking ECM or at least crank trigger I towed it to my shop and started to check things. Why I did it I don't know, but I cycled the main kill switch and it started! Real RELIEF!

I've spent the better part of the afternoon chasing parts and found a couple numbers you might want to add. Joyner USA Mesa Arizona Parts-JD (480) 882-9612 http://joynervehicles.com/ JMC Motors Chandler Arizona Parts-Casey (480) 545-1693 http://www.jmcmotors.us/ No Limits Powersports in Arlington Texas - Parts-Justin (888) 400-1151 http://www.cleanharleys.com/home (No LimitsPowersports) Sadly, there are no rear swing arm bushings available. Joyner USA ( http://joynervehicles.com/ ) did have an updated parts print out in thier download area that shows bushing kits, so maybe things will get better! Any input on my bushing replacement would be nice.

My problem was often the internal C clip would pull out of the axle bell at the wheel. What happening with yours? Kinarfi Kinarfi, I didn't answer your question! I guess I got on a rant! Both axles pulled the ball and cage assembly out of the cup destroying the small snap ring that is just internal of the cup. (I should get a pic of axle less cup) I just appears to be way too much suspension travel. With the broken swing arm mount, cracked frame, and swing arm bushing wear I'm thinking the combination of the three is the core of my problem. I haven't disassembled the right side yet, I can check axle/swing arm clearance as you suggested.

First, thanks Rocmoc for moving this string! I knew we were getting away from the main power switch topic and I didn't know how to move it. (Just a Newbie!) Thanks Lenny for the links. I read thru them and maybe I have an idea of what to do here. I will try to get some good pics of my frame and control arm mount breaks. I'm also going to really inspect my control arms. Another question I had was what should I expect from bushing wear in the swing arm bushings? There isn't another T2 Trooper for a couple hundred miles from me to compare. Like I said earlier, I bought this thing used, based mostly on cost and the fact that I feel I can work on it. Besides, if you buy used it already has that first scratch thing done! I have repaired a non-working cooling fan (bad connector), fixed inoperative wench (power lead left off), diagnosed fuel guage problem (guage) , and replaced an axle in less than a 100 miles riding only to have the new axle pull apart on the first hard right turn with an open diff. I knew this poor old pony (2008) had been put away wet, just not to the degree I'm finding! On the good side, it is fun to just easily ride thru where the high dollar guys are having fits! When it runs and stays together it is what I was looking for. Thanks all for your input, I'm learning alot in here!

Left side rear axle is pulling apart. It will pull the ball cage assembly out of the cup. I disassembled it last night. Found frame breakage at the swing arm anchor point and lower frame rail tube. I'm not sure how much play I should've found in the rear swing arm bushing, either. This is a used buggy I bought. It already had shock restraints on it. It's not been a very happy ownership yet!

I too had a master switch problem. I store my T2 in a warehouse so when I was in there I would always start it and let it warm just to know all was well. For no reason one day it wouldn't start. It would roll over only. No spark or injector pulse, (checked with a GM noid) but lights and accessaries worked. Thinking ECM or at least crank trigger I towed it to my shop and started to check things. Why I did it I don't know, but I cycled the main kill switch and it started! Real RELIEF! Now if I could get past my axle problem,,,,,,,,,,