My cousin has a 02 500 scrambler 4X4 and was riding it down the road yesterday and started making scretching sounds from the rear transmission and when he got home noticed a few drops of fluid on the ground. Then later on he took it for another ride and the sound got worse and more fluid leaked. We flipped the 4 Wheeler on its back and could then see the underside and noticed the case from the front sprocket to the bottem is cracked. Is this a common issue and has anyone had to repair this. Thanks for the help.

 

Your looking at replacing the case half at least. Did he just tighten the chain recently? Was he jumping? Even on the concentric models if the chain is too tight it can do this with some serious jumps. If you have to get into the tranny look into replacing the chain inside. It may not really need it, but since your in there it's a good time to do it.

 

Hopefully you have some mechanic skills so you and/or your cousin could just get a repair manual and do it yourself. If not, the dealer usually gets you up the a**.

I see this happen a lot, especially when the chain breaks or from running a chain too tight.

 

I have some skills but my garage is filled up with a 92 Suzuki King Quad that the 4wd is not working so I am in the process of pulling that out and finding out what the issue is there. Tim does not have much in tools, time or skills so its not looking good for his wallet. He called the dealer this morning and they are saying its about $500.00 just in labor and advised him to try and find someone that could weld the crack. Do you guy thing this is a bad idea? It sounds like a bad one to me however he just got the unit a month ago and his wife is not very happy so he does not want to tell her its going to cost about $700.00 after he just bought it.

For those who have made this repair do we have to pull most of the back end out or can we remove the sprocket and unbolt and bolt the new one on?

 

I just saw a used Scrambler Trans on Ebay for $100.00.