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 Post subject: Pilot Front End work
PostPosted: Mon Oct 30, 2006 10:50 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
Hi All,

My Project among others.... is to maintain my front end and steering on the Pilot.

As a back ground this is the "Wheelman Pilot Project" from years ago. The board came together and built a ride for Mr. Wheelman. It has been passed along the way and I am the current proud owner of it. Thanks everyone!

Be that as it may.

I need to perform some repairs and upgrades to this setup.

1. Works shocks need over haul. np send them off if I can get them to respond....

2. Ball Joint replacements.

3. Replace Left side tie rod end. (Right is new) easy

4. Steering has a loose play that is additive from steering wheel to actual wheels. Shaft repairs. Bump steer bushing, bushing , bushings. :)

5. A Arms: loan to friend to look at.

6. Breaklines...... I was a dumb ass and let my braided brake lines come in contact with the rim.....


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File comment: Left side
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File comment: Left Side frame mount point
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File comment: Left Side bumper Steer end. Inside Tie rod end.
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File comment: Left Side Tie Rod end
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File comment: Left Side Lower ball joint
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File comment: Right Side. Steering angle is huge on this side vs the left side....
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 Post subject:
PostPosted: Mon Oct 30, 2006 10:52 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
More


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 Post subject:
PostPosted: Mon Oct 30, 2006 10:54 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
More


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 Post subject:
PostPosted: Mon Oct 30, 2006 11:09 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
Upper Arm's OD is 7/8"
Lower Arm's OD is 1"


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 Post subject:
PostPosted: Fri Dec 29, 2006 9:01 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
I started to pull the parts off.

Arms go out to get Bushings made to fit.

Shocks go off to Works to get over hauled and adjusters added. Hopefully dropped an inch as well.


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File comment: I allowed the brake line to slack and it rubbed the inside of the rim.
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File comment: lesson learned: take huboff BEFORE removing the arms....
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File comment: frame mounts
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 Post subject:
PostPosted: Fri Dec 29, 2006 9:54 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
http://pilotodyssey.com/wheelman.htm


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 Post subject:
PostPosted: Sun Dec 31, 2006 3:42 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
Got the Arms of and them seperated from the Hubs.

I see some numbers. We'll see if they amount to a new part #.

With all the frnt end apart. My steering is still real tight.
Next step after this is to rework the steering with a good douching, inspection, and bushings.


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File comment: tough to get a pic of this. But its the leaky seal on my shock.
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 Post subject:
PostPosted: Sun Dec 31, 2006 4:03 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
MassOdy wrote:
Got the Arms of and them seperated from the Hubs.

I see some numbers. We'll see if they amount to a new part #.

With all the frnt end apart. My steering is still real tight.
Next step after this is to rework the steering with a good douching, inspection, and bushings.


The guy that made the kit for the front of your Pilot was
HI PERFORMANCE A.T.V. 246 Denny Way El Cajon CA 92020 619-448-8802

That is the return address that was on the info he sent me about 12 years ago.


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 Post subject:
PostPosted: Wed Jan 03, 2007 12:17 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Got the scanner working...


Attachments:
hiperformanceATV-.jpg
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 Post subject:
PostPosted: Wed Jan 03, 2007 12:20 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Here is the rear suspension.


Attachments:
hiperformanceATVrear-.jpg
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 Post subject:
PostPosted: Mon Jan 08, 2007 2:07 pm 
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Joined: Mon Dec 22, 2003 9:04 am
Posts: 465
Location: Springfield Ohio
Hi-Performance ATV went belly up 12 years ago. I used to frequent there shop while I was a student working on the Mini-Baja car at SDSU. As I recall they used the tie rod end from a VW for the upper ball joint and a Jeep tie rod end for the lower ball joint on there 3 to 4 wheeler conversion kits. We used there arms and knuckles for the Mini-Baja cars suspension.

Your upper ball joints look like the VW part but the lowers do not fit what I remember (not that my memory is worth a darn). I know it’s not a lot of useful information but maybe a place to start.


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 Post subject:
PostPosted: Tue Jan 09, 2007 8:23 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
that's awesome to know. Thanks Lee.

I actually spoke to them on the phone. Well left my name and number and spoke of my needs. She took it down and I'm waiting. I'll call back.

It was a long shot anyways.

Thanks again.


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 Post subject:
PostPosted: Sun Mar 04, 2007 9:52 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Any updates Mass on this by chance?


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 Post subject:
PostPosted: Sun Mar 04, 2007 10:54 am 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
Yeah I have.
Hare was so kind he got a lead on parts and bought me the stock front Arms, tie rods, shocks, new bushings and the arm are clean and painted.

My plans originally were to send these out to be rebuilt. The Arms need new ball joints. And one works ressi shock needs oil and gas. The arms need bushings too. These are +4" arms.

But, given the terrain I ride in the LT is over kill for me.
I'd prefer maneuverability.
And I KNOW my riding buddies would like me to as well.

And Mudbogger: you were so nice to send me a replacement steering shaft. Thank you.

I don't think I will keep a hold of the LT setup.

I've already been contacted from a few of the board members for these or wanting information.


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 Post subject:
PostPosted: Mon Mar 12, 2007 9:47 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
Started to install the stock rebuilt setup.

I'll miss the LT Works Shocks.

But here we go. In order for me to get this ride from my garage to my friends shop I got to get the front end together.

In doing so I cleaned up my front hubs and brakes. (work in progress)

The carriers have been modified. I hope the stock steering still fits.
Is carrier the right term?? The bitch ass part that connects the upper and lower A arm directly. ;)


Attachments:
File comment: what bear this was
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 Post subject:
PostPosted: Mon Mar 12, 2007 9:59 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
1 more


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 Post subject:
PostPosted: Mon Mar 12, 2007 10:07 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Going by memory they welded on a tab to relocate the tie rod end, is the ball joint tapers and holes the same as Honda or did they ream out the holes?


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 Post subject:
PostPosted: Tue Mar 13, 2007 12:46 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
I'm worried of this as well.

I'll put the pieces together tonight and see if they are sloppy.
I hope not. Otherwise I'll need replacements.

I'm also hoping the steering wholes are close enough for government work.


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 Post subject:
PostPosted: Tue Mar 13, 2007 9:02 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
Confirmed. The wholes for the Ball Joints are reemed out a tad.
And in a tapper.

Maybe these should go with the +4" Arms. Or sleeve them.

As I mentioned in chat I need to mic these out. And then compare to stock.
They match the mod well so maybe its best to replace them.


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 Post subject:
PostPosted: Wed Jun 06, 2007 9:56 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
I got the replacement Front Knuckles from Service Honda today.

Yipppeee still available!


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 Post subject:
PostPosted: Wed Jun 06, 2007 10:03 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
mo pics


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 Post subject:
PostPosted: Sat Jun 09, 2007 6:42 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
I built the hubs up today and snapped a few shots.

I used a bit of silcone sealer between the plate and the parts that attach to it.
I noticed when I took it apart it had trapped some crud in between.

I also ran the dremel with a soft brush over the parts. Got the residue crap off of the nuts and bolt heads.. Used a tight brush for the crater head bolts.
(wife thought i was crazy)

I noticed some of the 12mm bolts thread tips had rust and other did not.
Two bolts are exposed on there tip end to the elements. So I dabbed a tad of silcone on them to protect.


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File comment: pretty refurbed bolts
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 Post subject:
PostPosted: Sat Jun 09, 2007 7:19 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
MassOdy wrote:
I built the hubs up today and snapped a few shots.

I used a bit of silcone sealer between the plate and the parts that attach to it.
I noticed when I took it apart it had trapped some crud in between.

I also ran the dremel with a soft brush over the parts. Got the residue crap off of the nuts and bolt heads.. Used a tight brush for the crater head bolts.
(wife thought i was crazy)

I noticed some of the 12mm bolts thread tips had rust and other did not.
Two bolts are exposed on there tip end to the elements. So I dabbed a tad of silcone on them to protect.



Looking good.

Did you grease the ball joints?

Put never seize or grease on the tapers before installing?


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 Post subject:
PostPosted: Sat Jun 23, 2007 12:15 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
So I noticed the front hub bearings needed replacing as well.

And once I got them apart I notice the two collars were marked up a bit.

These parts are #2 and #5 in the parts pic,
44312-VN0-000
and
44620-HE0-000

How critical are they for being perfect?

The linear marks on them and th eheat stress it looks like on the outer side is concerning me.

New bearings and dust caps will be going in.

Will post more. gotta resize pics


Attachments:
File comment: Collars are #2 and #5
front_wheel.jpg
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 Post subject:
PostPosted: Sat Jun 23, 2007 12:21 pm 
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Joined: Sun Dec 21, 2003 11:24 am
Posts: 802
Location: Bolton Ma
pics of the collar bushings


Attachments:
File comment: hard to see but interior wall has a groove
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File comment: the other one
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File comment: these are the other parts. they are worn on the outside wall only.
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File comment: exterior wall shows what I see as heat stress??
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File comment: Here's Mud in your eye Kid
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