660 rear differential and chassis rebuild

This is the second 660 chassis I've had to read mount the diff in.This one is bad.I'll post pics as I get stuff ready for surgery.Yamaha would replace these chassis for this problem.When I'm done that diff won't move.If you own a 660 and have repeating axle breaking in the back it's caused from chassis deflection.A diff saver would fix the problem but this one is way beyond that.
Pics to come.

Really sounds interesting I will watching your pictures, for sure.

I got it stripped down earlier today.It's been welder a few times it looks to me.But it's bad news either way. I started getting it repositioned before I quit today.I'll get pics up of that tomorrow.

The back tube running horizontal has been but welded together.I'll be removing it too.prob bump the size up to 1 1/4 .120 wall DOM to help stiffen it up.

looks like the 2nd one to let go recently on here ,  hate to see such carnage   good luck on the repair

I just did one last winter.That guy had the engine cradle pushed up over an 1 1/2 ".It would even shift anymore.The diff tabs didn't look this bad but they still needed replaced.I cut the hole bottom out of it and started over.They just need to be properly jigged before you cut everything loose.

geterdun

You have your work cut out for you, but I bet you enjoy a challenge, want to see more as you go.

nothing like some good fabricating making  some thing better than it was to start with     

I am putting on my diff reinforcement bracket today I hope this is not common on 2008's to.

That's what I have is a 08 700 and it's not built anything like the 660 in the back. they changed some things for the good in the 700 chassis but a diff brace is still not a bad idea.

One side of the diff jig is welded.to the chassis. The other side is clamp in to get all if the pieces to fit right.Bear with me as I get the pics in order.

Both of these tabs were file fit to the frame rails with a caliper to insure that it's level to the frame rails.

On this pic you will see a short piece of tube slid over the smaller tube. this insure that once everything is in place that the diff is exactly where it was left and right in the chassis from the factory.

This is what it looks like from over head all put onto place.

In this pic you can see the hole in the diff has been egg shaped.This is a custom bolt that Yamaha makes in this size.So it's not common to find one one this long or longer in stock anywhere.What I plan to do is bore the hole in the diff to 7/16 so that I can take the slop out of the hole.If you give it an inch it will take a mile sorta thing.it's no big deal to bore the holes in a different diff if this one should fail and it only helps to go slightly larger. there is plenty of beef in the boss on that diff. the gold bolt is the 7/16 replacement before I bored the hole so as you can see it's already there on this end.

On this pic I show the mach up of the new diff tab before I cut everything loose.It fits perfectly into position. I may rewrite the program to put the diff support on the diff tabs for less crap going on in the back of this thing.In my line of work with my business this is not a challenge.This is what I do on Heavy Equipment so this little Rhino is in good hands. Lol Why buy a new chassis that is problematic for more money when you can have it redesigned for less.
Disclaimer: All products have their faults but this is no Polaris so we're golden everywhere else. Lol It will prob be Mon. before I'm back on this project.Any questions feel free to call any time at 419-953-8509.If I don't answer I'll only be sleeping for a few hrs. Lol

looks like your ready to go in the production of rear mounts , that mount is sweet    did u use a cnc plasma to cut out , very nice set-up on diff to keep in place ,   on the mount tab hole your boring out   would there be enough area to install hardin bushing might hold up longer than the aluminum housing

That's some nice work,looks great and should last forever!!

very nice!!

Thanks for the props fellas.I'm on my way back out to work on this thing.I'm bored and I can't start my project till I get the lift back.Finally going to pull my 08 out and start the demolition on it.I'll start that thread on here.Project "Rhino Resurrected"! Fuel tank relocated,6" seat drop,6"boat side,bed delete and crab cut.I have a guy coming over after I get the shell done and we are doing some carbon fiber parts for it.Make it look mean then buy a JBS motor and make it mean.lol

Jason I can start to see the thought process, that jig to align the rear diff and that the support over the top is cool.

Baxter Built Fabrications wrote:

Thanks for the props fellas.I'm on my way back out to work on this thing.I'm bored and I can't start my project till I get the lift back.Finally going to pull my 08 out and start the demolition on it.I'll start that thread on here.Project "Rhino Resurrected"! Fuel tank relocated,6" seat drop,6"boat side,bed delete and crab cut.I have a guy coming over after I get the shell done and we are doing some carbon fiber parts for it.Make it look mean then buy a JBS motor and make it mean.lol

ive always wanted to do that...you da man