My friend Drew started the disassembly of the bearing carrier and reassembly with the right size bearings. Couple of notes, on the type 16 bearing carrier you need the "smaller" bearings NSK Bearings (made in Poland) 6206DDU/6206DDUCM/D EEMS5. The dust shields do NOT fit when used with the spacers. Try as you may, there is not enough room. We figure that the "new" style bearings are sealed and the old style bearings where open and needed a dust shield? Who knows, but with the install of new bearings just completed it is what I'm going with.
With the bearing carriers finished (for the second time) the installation of them on the rear suspension arms was next and then the install of the Koni shocks, small diameter springs, rubber damper and spring cap. I carefully poured enough engine oil in the shock tubes until they leaked out the top with the shocks placed inside the tubes and screwed in the retaining top and assembled everything. It all went together very easily and I got ready for next step.
Everything was fitting just as expected so I thought the install of the TTR 3 bolt flange drive shaft would be a piece of cake. Well, the drive shaft bolted just fine to the differential half shafts.......but I could not get the rear rotors to fit the bearing carrier half shafts and the drive shaft. The rotor holes would not align. I tried everything I could except drilling the holes out on the rotors. Darn! It's Sunday night so I have to wait to call TTR until the next day. Never the less, bolted the wheel hubs on, torqued them as per instructions and mounted the wheels!
As usual, I'm waiting for parts so a couple more days of delay until the entire drive train and suspension is together. But the chassis is finally back on its own wheels!
Spoke with my engine builder on Sunday. They did the initial run on the dyno and at 6500 rpm and 147HP it flattened out. They couldn't figure out why a flat spot so they are talking to the cam builder and checking the timing chain gear adjustment. I'm being patient as this part of completing the engine is critical to the final tune.