Rear differential bolts / technical service bulletin

hey guys, i recently noticed my rear end making some popping noises, so i searched around and found out about the under sized mounting bolts for the diff. so i ordered up a trail logic support, and i am going to put some 7/16 bolts in place of the old ones.

i tore it apart tonight and the 7/16 are just a hair too big, they slide almost all the way through, but there is a tight spot on one end of the housing, so it needs to be drilled.

did you guys pull the diff out to drill the holes? its pretty tough to get in there with a drill, so did you use an extra long bit, or did you pull the housing? if you pulled the housing, does the rear drive shaft just slip off? will it drop down enough to get it in a location where its easier to reach with a drill?

also, does anyone have a link to yamahas service bulletins? i read somwhere that this was a tsb from yamaha, but i cannot find it. might be a dealer only thing, but i am sure its on the net somewhere. any info would be great.

got the 7/16 bolts in today. used a 7/16 bit with a go-go-gadget custum extension to reach the holes. there isnt much to drill, just a touch of a high spot in the rear end housing. bolts fit perfect after a quick sweep with the bit. NO MORE REAR END CLUNK!

someone should make this fix a sticky. with that rear end flopping around, i would think that would cause some damage after a while. i cannot believe yamaha let that one slip.

Good info. What was the length on those? I'll get me a set tomorrow.

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i think i used 5 1/2" bolts. the stock ones were 1/2" shorter, but thats what i had to use to get the right shaft length.