Hey guys I am new at this whole ATV thing and need some help.
Went for my first long ride with my Scrambler and came home to find out that my gearcase has a huge crack in it [img]i/expressions/face-icon-small-sad.gif[/img] . Was wondering if this was a common problem and what would be the best way to go about fixing it.
Right now i have a few options:
1: Take it to the shop and pay half the price of the quad.
2: Get the parts and do it my self
3: Have a friend weld it back together

Was wondering what everyone else would do. I have a good mechanical background so i don't mind doing it, and my friend says he can weld it with no problem at all.

Also if maybe anyone has a used tranny someplace let me know. JJerome49@yahoo.com

 

Welcome to the forums.First thing you need to do is find out what cracked the case.I see no problem getting it welded.You should have no problems doing it yourself.You should be able to get all the help you need right here.

 

I would weld it too.....we have done it before....just make sure that you completely gut it, and cover all of the holes where burrs can't get into them. There used to be, not sure now, but a bolt on the bottom of the tranny, near the skid plate, that goes from the tranny to the frame....its purpose is to keep the tranny from moving under torque, make sure that is tight, make sure your bottom bolt is tight, and make sure your swing arm bolts are tight.

 

I have no idea what caused it, just found it that way after i got it home. I will make sure i check those bolts though, would that have caused it if there loose? and another question I forgot to ask is how hard is it to get the case off, is there going to be springs and gears flying out at me?

 

Try to get photos of it. In frame and out. It may help us diagnose what happened and figure out the best repair.

 

When my 00 scrambler was new the tranny cracked and the dealer said itwas a problem with that year and it was a 4x4 only thing.He said it was something to do with the clutches ( sounded like bull to me but It was replaced for free).
Now that my scrammmy is a 2x4 the only way i broke the tranny was from jumping and the frame broke cracking the tranny.
Look for the frame to be broke Between the battery and the clutch cover.look at the frame there to see if the flatter piece that holds the tranny supports(at the rear of the tranny) broke off the square tubing(it will be under the relay) also check the frame on the other side,it brakes under the piece of plastic the covers the rear brake ad the swingarm bolt.It some times brake right where the swingarm bolt support and the sqare tube.(right between the two bot that hold on the plastic piece).

If the frame is broke or cracked at these spots it could have caused your problem.

One last thig MAKE SUR THE SWINGARM is tight -if it moves side ti side it can brake the tranny case.

You didn't say where the crack was so i gave you a idea of what can cause this.

 

Sorry about that, it's brok on the right side where there is a little circle comeing out that says Polaris on it. It starts at the bottom and goes to just about the middle of that circle. I will hopefully have soem pics on here later as soon as i can get my camera to work.

 

Sounds like the swing arm bolt was loose to me, or atleast that is what first came to mind.....or if it wasn't loose, it could have had bad bushings....

 

I don't have it all the way apart yet but I think the bushings my be low on grease, is this a possibility and should i replace the bushings?

 

Them being low on grease wouldn't cause your gearcase to break, most likely your swing arm bolts just came loose. I couldn't ever keep mine tight on my sport, finally after a few chains I decided to weld the bolts in. If you have your swing arm out, it is probably a good time to replace the bushings and the little plastic orange washers. (That is why my sport had, yours may be different)