Tools Needed...

Suzuki Club UK - SCUK - Replacing UJ Method 2

Stripping the old joint...

Suzuki Club UK - SCUK - Replacing UJ Method 2

Remove prop shaft. 4 bolts. May need a slight tap with BFH to release it from the flange.

Remove all four cir clips.

Suzuki Club UK - SCUK - Replacing UJ Method 2

Place UJ/prop on a surface which is strong but will allow the bottom cap to fall through (all will be made clearer in the following pics). An old bearing is ideal.

Use an old spark plug socket (or similar) which fits through the yoke holes and let rip on the UJ with the BFH bashing down on the UJ cap.

Suzuki Club UK - SCUK - Replacing UJ Method 2

Until the bottom cap pops out.

Suzuki Club UK - SCUK - Replacing UJ Method 2

Prize it off, (taking the time to admire all the little needles that fall out).

Suzuki Club UK - SCUK - Replacing UJ Method 2

Turn prop yoke by 90* and repeat process to push off the cap on the other side.

Suzuki Club UK - SCUK - Replacing UJ Method 2

You should now be able to wiggle the cap-less UJ off the flange yoke.

Rotate the prop 90* and repeat the same steps for the other half of the UJ.

Suzuki Club UK - SCUK - Replacing UJ Method 2

Gather up all the bits (except the prop shaft and yoke) and throw them at your neighbor's dog.

Suzuki Club UK - SCUK - Replacing UJ Method 2

Rebuilding the universal joint...

Suzuki Club UK - SCUK - Replacing UJ Method 2

Find your replacement UJ. I've prefer the genuine zook ones, part #27200-73813 for the 'fatty' props. They don't have a grease nipple like some after market ones I've used but last longer for me.

Suzuki Club UK - SCUK - Replacing UJ Method 2

Insert the cross part on the UJ into one of the yokes and gently tap on one of the pre greased caps until the groove in the yoke is visible.

Suzuki Club UK - SCUK - Replacing UJ Method 2

Insert the cir clip and repeat for other side.

Wiggle the other yoke over the two cap less ends of the UJ and repeat the process of gently tapping the caps on and securing with cir clip.

The last cap to go on can be a bit tricky so the use of a mates finger to press it down whilst you insert the final cir clip may be needed.

As it was hot out side, I was on my lone some and I had cold beer waiting for me I retired to the confines of the shed and used the press.

Substitute the bolt in the picture for mates finger.

Suzuki Club UK - SCUK - Replacing UJ Method 2

Re fit prop to zook after re greasing the splines and lining them up properly with the punch marks on each end of the telescopic bit.

Remove beer from fridge.

Sit in sun.

Drink.

Enjoy.

Suzuki Club UK - SCUK - Replacing UJ Method 2

Credits...

This article was written by Simon Owen

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