Its sad but true, im screwed. =c(

My polaris transmission is entering the final stages of a slow painful death. last year i noticed that it was making an odd sound, a sort of throb like a gear was hitting the side of the case, so i knew it was dying.

now the "throbb" is worse, and when i changed the transmission oil discovered metal shavings in it.

so i've got a few questions...

A> how much will this transmission cost me?

B> Can i replace it myself (my father and I are reasonably competent mechanics, last summer we replaced the engine block in his truck after a cylinder leak screwed it up)

C> how much would it cost to do it myself vs professionally

D> Is it fricken worth it!!


thanks guys.

-fed up with this polaris 4-by-crap.
Alaska weather and conditions are the truest test of any machine, trust me, and this just cant hack it reliability-wise. Honda forever!!

 

What type of bike is it? I have an sp-500, and understand that the transmission on it costs about $1000 for just the transmission itself. Depending on the year model you have (if it is an older model than say 98) you may be better off just buying the whole thing preassembled. My dealer service guy says that they've changed up the guts to the sp500 transmission since 96, and the later model is by far better.
I'm assuming that the shavings are aluminum, meaning that something is wearing into one of the side cases. I would take the thing off the bike and disassemble it to see what's wearing. Make diagrams of how it all comes apart, to ease reassembly if you have it apart for a couple weeks or more. It may be something rather minor, but the only way to find out would be to take a look at it. If one of the side cases is worn, you may be able to buy just the side case to replace the worn one, or the worn one may not be worn bad enough to warrant replacement.
If you do decide to replace the whole unit, you may as well run the other one until it dies, unless you go on long runs away from home. Keep us updated on what the outcome is.

 

Thomas....
What year model and make is it?..
If its the older transmission.. A chain drive transmission... NEVER FEAR!!...
You will actually spend more time pulling and putting the transmission that the repairs themselves..
Just remove it (with the oil drained) lean it on its side and remove all the bolts.. Then pull the case apart... In there you will probably immediately find that you drive chain is stretched and hitting the side of the case... Thats what usually wears out... Simply buy a new chain, the three new seals, a quart of chaincase oil.. and pick up a tube of ULTRA COPPER RTV Gasketmaker from an autoparts store..
There is NO gasket for the chaincase.. It just uses RTV..
Also, INSPECT the shift forks, gear-teeth, bearings..etc... and replace as necessary..
If none of that helps.... sell it and get your Honda...

 

i broke the chain and cracked a shaft in my sport 400 tranny, my dealer only charged $300 total, works like new now... Tips( let off when jumping and landing and dont slam it forward in to gear if the engine is revving, you know the grinding sound!)

 

Yeah,
Im trying to remember exactly which episode caused the transmission to start popping...
It was either when my son was sitting at the edge of a big mudhole with the throttle pinned wide open and the front tire wedged against a tree stump... He purposely did this all day that day to cover his uncle in mud ( he was the next rider in our group..)
Or it was the next time we all went riding when MY SON.. (again) would think he had shifted into gear and would give it the gas.. it would be in neutral, so he would jsut reach over and start CRAMMING it into gear... HHMM... NOT A GOOD SOUND!!..
HHHMMMM...... Maybe I oughta ground him.....???.

 

Well... You had a great idea about the chain but i just checked the manual, ive got a gear-type transmission....arrghh!!..

Btw I do have a honda fourtrax 300 right now (1990). Not a single problem with it ever...except for right now.....

as i said, alaska is the truest test of an atv and its held up damn good....i jump it and bottom out the shocks, cross rivers (some guy emailed me who lives in town - Ive crossed the chena river in my fourtrax man!!!)....but a couple weeks ago i noticed the rear-right wheel wobble so i put the machine on its side and examined it... hmmm loose wheel nut so i tightened it and all was a-ok until i pulled on it and it.....fell off.

watch your rear wheel nuts!!! if they aren't tight and you think "hey the cotter pin is in there and its reasonably tight" is ok, your wrong!! my threads actually corroded all the way off....so the next time i went atv'ing it could have fallen right off at 40 MPH.

anyways... im suffering from deprivations. i really feel horrible right now. I dont know what to do. I havnt been fourwheeling in weeks..... arghh!! heheh.

Later