I'm playing hookie from work today and debating dropping the diff out to install the 3.63s. Is there a shop around here that can set the pinion depth and backlash? That's the only part that is out of my comfort zone.

Thanks,
Pat

 

i did mine myself but I reused the pinion depth spacer and crossed my fingers.

 

I'm about to try the same. Was it really that difficult?

It looks like measuring the pinion depth is the most involved part. Backlash shouldn't be a problem. Distance between the bearing carriers is easy...

I posted this just before 11, went outside and had the car in the air 20 minutes later. By 1 the Diff was in my lap. That beats the hell out of anything VW related

 

nope... It's not that difficult... Did mine the same way Y8S did.

 

Did you guys use a new distance piece? New pinion bearings?

Everything looks to be in order; no wear, no leaks.

 

I used a new distance piece. you'll also NEVER get the pinion bearing off. debatable if you can get the diff bearings off. get new seals. that's all you need.

dont forget the RTV seal. I did the first time. oopsie.

Backlash is beyond easy. you can get a dial indicator from mcmaster for super cheap.

 

I reused everything except the ring and the pinion.

Been working in my living room garage all night.

Mark

 

Ha. Awesome.

Do you need a factory service manual for that bike? I have one laying around downstairs I don't need.

 

What year. I have the 1st gen manual but not the second... The track bike is a Heinz 57 of all sorts of stuff. Some of it pretty trick like custom forks and shocks. I got that bike and the motor seized, which was a bummer, however it looks like the spare motor from the 89 bike is good. So, we'll see. You're welcome to come over drink beer and assist in the swap should you feel it. I am supposed to run this bike at the track on Saturday LOL.... Not sure that's gonna happen.

Mark

 

I am slacking.

En400 En450 Motorcycle Service Manual '85-'90
Ninja 500 GPZ 500S Motorcycle Service Manual Supplement '94

The two manuals cover every 500 up until the recent facelift. I wouldn't be suprised if they still apply. Kaw loved to slap that motor into everyhting they made with two wheels.