Gearless Locker 2 Suzuki

High Lifter Products, Inc.
780 Professional N. Drive
Shreveport, La 71105
www.highlifter.com
(318) 524-2270
(318) 524-2297
Suzuki Vinson and Eiger
Detroit Gearless Locker allows the ATV to be a true four wheel drive by locking the front differential so that it
delivers power to both front tires at all times.
Important Information
This product is designed for use on ATV’s which are primarily operated at low speeds in deep mud or snow,
where maximum traction from all four tires is desired. It is not intended for ATV riders who will spend most of
their time riding at high speeds or riding on hard ground. When the front differential is in full lock, more effort
is required for steering on concrete and other hard surfaces.
Warranty Information
Please read the warranty information before installation and operation. All warranty claims and problems
should be directed to High Lifter Products.
Installation Procedure
The Detroit Gearless Locker is easily installed in the field with two or three hours of labor required. The
procedure is similar to installing a conventional or limited slip differential.
•
Caution: It is recommended that safety glasses be worn when installing the product.
•
Caution: Read and comply with the manufacturer’s safety warnings and cautions.
•
Caution: Do not use heat to disassemble drive axles. To do so can destroy heat treat properties of the
material, weaken or distort axle components.
1
Note: When referring to the left or right side of the ATV, it will always be from the seated position.
Removing front drive shafts from the differential
1.
2.
3.
4.
Break loose the front tire lug nuts. Jack-up and block front of ATV until both front tires are off the ground.
Remove front tires.
Drain gear oil from front differential.
Remove the inner fender cover.
5. Remove the hub nut.
6. Completely remove shock .
7. Remove the lower ball joint nut and separate the lower A-arm from the knuckle /brake panel assembly.
8. Pull the knuckle/brake panel assembly away from the drive shaft.
2
9. Support the knuckle/brake panel assembly so that it does not hang from the brake hose. Do not twist the
brake hose.
(Note: Tie assembly up out of the way with rope or wire)
10. Give the drive shaft a sharp tug outward to remove it from the differential. Take care and brace the ATV
when tugging so it does not fall. Also, inspect the seals in the differential case for wear and damage.
For opposite side repeat steps 4 to 10.
Removing the differential
1. Remove the following:
n Wires from the switch assembly
n 2 mounting bolts and nuts
Switch Assembly
Front Mounting Bolt
Rear Mounting Bolt
Front and Rear Mounting Bolt (opposite side)
3
NOTE:
The Eiger does not have wires to disassemble. There is a cable that runs to the back of the differential
that needs to be removed.
2. Remove the bolts from the propeller shaft assembly .
3. Remove differential from the ATV.
4
Differential Case Disassembly
1. Remove Un-Locker Assembly
2. Remove cover bolts and carefully pry the cover off the case using a screwdriver at the pry points.
Remove the differential assembly from the differential case.
3. Remove the six bolts, then place the differential assembly with the housing side down, and remove the
ring gear.
5
4. Remove the following:
--differential cap
--cone spring
--shim
5. Remove all components in the interior of the differential housing.
Note: These components will no longer be used and should be stored for future use.
6.
Take the Gearless Locker out of the box and carefully remove the rubber band holding the Detroit
Gearless Locker together.
7. Insert the Gearless Locker into the differential assembly in the manner illustrated in the picture.
After the Gearless Locker has been installed into the differential assembly, and carefully remove the side gear
and clutch pack with housing. This will expose the cross pen and four holes that the springs will be inserted
into.
Once the springs are in place, re-insert the side gear and clutch pack with housing. Take care to line up holes on
the clutch pack housing with the springs.
6
8. Place the new cap provided with the Gearless Locker onto the differential assembly.
9. Place the ring gear onto the new cap, carefully aligning the bolt holes.
10. Carefully rotate differential assembly to where bolt holes are on top.
together using the factory bolts. Torque: 49 Nm (5.0kgfm, 36lbf ft)
Discard the two socket bolts, they are no longer needed.
Bolt the differential assembly
7
Note: Use LockTite on all bolts before they are torqued.
11. Place the differential assembly back into the differential case .
12. Place other half of the differential case over the assembly and close.
Torque: 10mm bolt (36lbf) 8mm bolt (19lbf)
Note: Use LockTite on all bolts before they are torqued. When sealing the differential case use a
solventless silicone (It is used for motorcycle snowmobile,
watercraft.)
Note: Make sure that the gear assembly rotates smoothly without
binding.
13. Re-attach the Un-locker assembly.
8
Differential Installation
1. Place the differential back into the ATV.
2. Re-attach the propeller shaft to the propeller shaft assembly
3. Using the mounting hardware attach the differential to the
frame and re-attach the wiring to the switch assembly.
4. Slide side axle into differential. Rotate shaft slightly to align splines.
9
5. Once the shaft is in the differential, take the knuckle/brake panel assembly and attach it to the CV shaft.
6. Re-attach the lower A-arm and ball joint nut.
7. Place hub nut back on hub.
8. Re-attach the shock.
9. Put wheel back on ATV.
Follow steps 4 to 9 for other side.
Gear Oil
Add 80w90 gear oil and differential gear additive supplied with the Detroit Gearless Locker. Make sure
to use all of the additive.
Caution: Do not operate the ATV if both wheels of the Detroit Gearless Locker
differential equipped axel are not driving. Power to only one wheel can cause serious
steering problems and loss of vehicle control and result in mishap, which can cause
property damage, injury, even death.
10
Installation Test
Step 1
With the engine turned off, raise driving axle(s) until all
wheels are out of contact with the surface. Place the
transmission in gear so that the drive shaft is locked and
does not rotate.
Step 2
With two people, rotate both wheels forward, as far as
possible to lock both wheels. (Both wheels should stop
after rotating a short distance.)
Step 3
With the right wheel securely held in the forward direction,
rotate the left wheel rearward. The left wheel should rotate
freely.
Step 4
With the left wheel slowly rotating rearward, the right
wheel should be rotated slightly rearward. This will lock
both wheels.
Step 5
Again, rotate both wheels forward, as far as possible to
lock both wheels.
Step 6
With the left wheel securely held in the forward direction,
rotate the right wheel rearward. The right wheel should
rotate freely.
Step 7
With the right wheel slowly rotating rearward, the left
wheel should be slightly rearward. This will lock both
wheels.
Repeat steps 2-7 except, test for forward
disengagement.
Operation Test
To check normal Detroit Gearless Locker differential
operation, drive the vehicle on a flat surface with good
traction, in a right or left circle in forward and reverse to be
sure that the outside wheel is free to overrun (i.e. that the
outside tire does not scuff).
11