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 Mettlers ATV & |
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Viper MX2000-MX3000 Bushing upgrade kit |
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This is an upgrade kit for the Viper Max MX2000-MX3000 ATV winches. This kit eliminates the gap between the sides of the spool and the support plates. It also offers support for the entire diameter of the spool. Bushings are milled from Delrin Acetal copolymer which has a tensile strength of 9500 psi. Also included in the kit is high quality retaining clip for the drive shaft return spring as well as a Delrin clip keeper. The bushings in the lower part of the picture are the stock bushings that get replaced. | |||
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$30.00 + $6.00 S&H |
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| Installation Instructions | ||||
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Begin by removing the top two allen head cap screws on the freespool side of the winch. As you remove the second screw you will feel the spring on the drive shaft begin to push the winch apart. The spring is under slight pressure. Take care to note how the winch comes apart and don't let any parts get away from you. Only remove these two screws. There is no need to remove the other screws. | |||
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As you separate the gear box from the rest of the winch several parts may fall out. Lay the parts out in the order you remove them. Inspect the parts for wear and replace as needed. It's also a good time to clean out any mud ,dirt ,etc. Here you can see one of the bushings that were going to replace. | |||
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Here you can see the drive shaft in the first planetary gear set as well as the other bushing. Pay attention to how the drive shaft is installed. Make sure the spring doesn't find its way into the gear box as you take it apart. The shaft should just pull right out of the gear set. Make sure you push the gear set back as far as it will go into the gear box. The gear set can actually come off the motor shaft and cause problems. When the winch is together the spring is what holds the gear set back as well as provide tension for the free spool mechanism. If the gear set happens to come off the shaft you should be able to turn it until it lines up with the motor shaft and fall back into place. | |||
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Here is one of two bushings that we are going to replace. They just simply lift out of the support plates. Set both bushings off to the side, they will no longer be needed. | |||
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Here is the other bushing that we are going to replace. They just simply lift out of the support plates. Set both bushings off to the side, they will no longer be needed. | |||
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Remove the small compression spring from the end of the drive shaft. It just slides off. Keep this handy it will be needed. Next remove the small "E" clip from the drive shaft. The stock clips don't fit very well and it may even be distorted. This simple little clip is probably the weakest and cheapest part on the winch yet can destroy the winch in just a few seconds if it comes off. | |||
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Here are all the parts that are being replaced. If you look closely you can see that the clip is slightly distorted. It was actually loose on the shaft. | |||
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Time for the new parts! The replacement clip fits much tighter and also has "ears" on it. The Old Timers call these "poodle clips" because of the ears. What this clip does is provide more of a shelf for the clip keeper to rest on. The clip will be tough to get on the shaft. I usually wrap a shop towel around the clip as I push it on the shaft. The towel gives you a little leverage and keeps the clip from flying across the shop if it slips off. | |||
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Next install the clip keeper with the pocket facing the clip. The clip will fit snuggly into the pocket. Slide the spring on the end of the shaft. When the winch is assembled the spring holds the keeper against the clip protecting it and locking it into place. The high strength clip along with the keeper ensures it will stay put. You can even cover the clip with silicone if you want. | |||
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Next install one of the new spool bushings on the motor side gear box. Align the dimple on the support plate with the notch on the bushing. Make sure the gear set is pushed back on the motor shaft. | |||
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Push the bushing in until it is flat against the support plate. It will fit just snug but shouldn't be tight. Don't force the bushing in with a hammer or punch. If it doesn't fit by using hand pressure only, check the plate for burrs or wear. | |||
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Again push the bushing in until it is flat against the support plate. It will fit just snug but shouldn't be tight. Don't force the bushing in with a hammer or punch. If it doesn't fit by using hand pressure only, check the plate for burrs or wear. You can apply some water proof grease on the bushings if you like. | |||
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Next I like to stand the winch on its motor to finish assembly. Install the drive shaft into the gear set. Make sure the spring doesn't fall off into the gear box. I usually hold the shaft in place and then install the spool. The spool will support the shaft and hold it in place while you install the other gear box. | |||
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Before you install the spool use some emery cloth or a dremel too remove the flashing from when the spool was cast. This flashing can cut cut into the bushings if it isn't removed. | |||
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Here you can see how the spool holds the drive shaft in place while you get the other gear box ready for installation. | |||
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Next install the other gear box on the spool. Keep in mind you have to align the spline on the spool and the drive shaft has to engage the gear set. This sounds tougher than it really is. Use a slight rotating motion as you lower the gear box on the spool. You will feel the drive shaft engage and you can see the spool engage its gear. Once the gear box is in place just install the two allen screws and your done. | |||
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Here it is all finished. You can see how the new bushings fill the gap in between the spool and the support plates. They will also provide support for the entire diameter of the spool sheave. I can't say this kit will make your Viper winch bullet proof but it is good improvement over the stock set up. | |||
| Before | ||||
 Here you can see the gap that the stock bushings leave. |
 This view shows how the stock bushings don't fully extend through the housing |
 Here you can see the small diameter of the stock bushing. |
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| After | ||||
 The new bushings fill the gap. |
They extend past the surface of the support plate using 100% of the plate surface for support. |
 Full diameter support for the spool. |
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Copyright 2008 - Mettler's ATV & Small Engine Svc. - All Rights Reserved |
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