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Old 02-27-2012, 10:10 AM   #1
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Speedo bearing installation '01 ZR 800

Quick question - jack shaft bearing on the speedo side completely disintegrated and I have to install everything new, from the cable coupling to the speedo adapter. My question is regarding the position of the two triangular bearing retainers in relation to the tunnel wall. Are they both inside the tunnel, sandwiched around the bearing, or is one inside the tunnel and one outside the tunnel behind the speedo adapter? The manual (and parts diagram) is vague and unhelpful, although one picture in the manual shows the speedo adapter installed and there does not appear to be anything between it and the outer tunnel wall. On disassembly, they were both inside the tunnel, but then again, it completely disintegrated (and the installer left out the solder rings), so I'm hesitant to trust that it was installed correctly. One respected blogger posted instructions that suggest that one retainer goes inside the tunnel and the other outside, beween the tunnel wall and the speedo adapter. So I'm confused. It seems to me that if I put one outside the tunnel, the square neck of the bolts will protrude from the single inner flange and bite into the round hole in the tunnel wall when I tighten it. That won't happen if the retainers are doubled up inside the tunnel. So I'm thinking the order of parts from inside to out is: locking collar, inner retainer, bearing, outer retainer, solder ring, tunnel wall, speedo adapter. Any thoughts out there? Thanks!
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Old 02-27-2012, 10:42 AM   #2
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one tunnel side and the other between the speedo adapter and tunnel
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Old 02-28-2012, 12:12 AM   #3
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zrt man is right - one inside the tunnel and one inside the speedo housing. and btw that is the driveshaft bearing, not the jackshaft
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Old 02-28-2012, 11:30 AM   #4
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See on mine they both were on the inside of the tunnel, with the bearings in between. The Speedo adaptor was on the outside of the tunnel. Mine is a 94 Wildcat 700.
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Old 02-28-2012, 11:42 AM   #5
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You can do it either way, but if you want to do it how the manual says, then both triangular plates go inside the tunnel. These pictures from the manual clearly shows it. The supposed benefit of having one on the outside and one on the inside is that you can change the bearing without removing the shaft.
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Speedo bearing installation '01 ZR 800-speedo.jpg   Speedo bearing installation '01 ZR 800-bearing.jpg  
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Old 02-28-2012, 12:53 PM   #6
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I know it's not a lot, but if you install them on both sides, would that not make the bearing slightly loose? I just replaced mine and the bearing seemed to fit nice.
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Old 02-28-2012, 01:55 PM   #7
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Wildcat, I put it in with both on the inside and you're right, the bearing fit perfectly between the two retainers. I wonder if the width of the tunnel wall between them would leave the bearing a little squirrelly?? Probably wouldn't be enough to make a big difference...tunnel wall is pretty thin. But it also seems that the square head of the carriage bolt needs the thickness of both plates to avoid biting into the round holes on the tunnel wall. Maybe next time I'll do one outside and one in. Thanks for all your help.
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