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Discussion Starter #1
Once again chasing a weird problem and want to get all the facts before buying parts.

Problem 1:
Every ride where we go through deep water, I end up with water in my front diff. Not a ton of water, but water nonetheless. Changed seals several times, no luck. All seals and tubes are tight to diff. When I drain the diff after a ride, oil is milky.

Problem 2:
Front right axle has slack in the spline where it enters the diff. You can move the cup up and down much more than you can on a new bike (I have checked).

Suspect:
When I pull the drain plug on the diff, the oil drains like it would if you were pouring water out of a bottle. Liquid out, air in, liquid out, air in, etc. In other words, there is no other source allowing air in while the oil is draining. HOWEVER, when I push up on the front right axle cup, oil drains faster. Air leak introduced. I suspect the water is getting in here.

The Ask:
Anyone who has a BruteForce 750 (or equivalent bike that has this same axle), has the axle out, and access to a micrometer, can you please measure the smooth section in-between the cup and the splines on the shaft that goes into the diff? Mine has some wear from previous abuse and it measures .864". The 5/8"socket that I stuck in there and has the correct amount of play measures .868". I want to know if an otherwise good axle actually measures somewhere around .868". If so, then I can buy an axle and solve my issue. If not, then I am out of solutions!

Been fighting this for months. Any help would be great!
 

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Discussion Starter #2
As an update to this and if anyone else has the issue, here is the outcome. The tech at Rocky Mountain ATV was the ONLY person out of 14 attempts with about 9 companies, to take the time to measure a new axle for me. For that I am grateful! He confirmed that the shaft size is .868", so it is plausible that my .004" of leak causing excessive slack will be rectified by a new axle. I ordered a Tusk replacement (had very good reviews) and some new tie rod ends (popped one on the ride this past weekend).

If you are looking for a place with great customer service, Rocky Mountain ATV is a great choice.

Will post back after I get it in.
 

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As an update to this and if anyone else has the issue, here is the outcome. The tech at Rocky Mountain ATV was the ONLY person out of 14 attempts with about 9 companies, to take the time to measure a new axle for me. For that I am grateful! He confirmed that the shaft size is .868", so it is plausible that my .004" of leak causing excessive slack will be rectified by a new axle. I ordered a Tusk replacement (had very good reviews) and some new tie rod ends (popped one on the ride this past weekend).

If you are looking for a place with great customer service, Rocky Mountain ATV is a great choice.

Will post back after I get it in.
I've been shopping on Rocky Mountain for years I absolutely love them you can't beat their prices and the rewards cash is great
 
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