I have a 95 Big Boss 6x6. I plow snow in the winter with it and a cycle country 48" blade.

The output shaft snapped cleanly in two, Luckily the break is ahead of the rear drive sprocket, so the rear wheels work.

I seem to have three options:

weld the old shaft back together,
spend $149 for a replacement part,
buy a used trans on ebay.

Anybody ever hear of this before?

How do you break the output shaft in two?
Anybody rebuild their own trans? Looks like it might be a fairly straightforward job.
Comments and advice welcome.

lester

 

My old 425 Magnum did the same thing.If I were in your place I would pull the tranny out and take it apart to see what else is worn on the inside and if it was in decent shape get the shaft and put it in.These gearcases arent that hard to work on if you have a manual.

 

Thanks FLH,

I have a shop book and was planning to rebuild the broken unit. Glad to hear this might be something I can do
on my own. Does anybody make a rebuild kit? or do you just replace whatever is worn?

what year flh? i had an 78 1/2 fxe.

ltrrtl

 

You will have to get what parts you need they dont make a kit.The only things you may need is shift forks if they are worn any at all and a new internal chain(good idea to replace it when apart) I ride a 1972 FLH that I have had since 1987.

 

Thanks for the reply. Hope your weather is still good enough for you to be in the wind.

 

FLH,

Thanks for the encouragement. I was able to get a new shaft and reinstall it with a mechanics help to get the bearings on the shaft.
Manual shows using a battery puller to remove the shaft bearings. What a Joke! Glad this guy had pullers and shims so I did not damage the bearing races.

Pretty darn simple as you said. Did not even have to deal with any of the other shafts, gears, or the gearchain in the case. Gears looked perfect and no wear on the shift forks.

The outer shaft bearing was shot, needle bearings all gone. Got a new one and some new drive sprockets and now I am ready for bear.

Thanks again for the encouragement!

lester

 

Congrats on the tranny.These things arent as bad as they look.

 

aklester glad you got you bike back together. It gives me encouagement to work on my bike. I also bought a shop manual for my bike. And a batter puller isn't good for annything but a battery. lol

 

I have a very similar problem. My output shaft also snapped , cleanly, like you encountered. My 1997 Scrambler 400 has been reincarnated as a Bay Boy Bike, as my teenage nephew puts it - It's not even recognizable! Anyway, he swapped the original H/N/R tranny with a Magnum 425 H/L/N/R, extended the swingarm about a foot, & upgraded clutch/exhaust/engine overhaul, 12x26 Mud-Bugs & chrome rims, new plastic all around, new seat, etc,(He worked at an ATV shop and was getting paid by parts in lieu of cash). Question I have is which H/L/N/R tranny's are compatible with the 97 scrambler engine block? It's kind of nice having the low gear at times. I found a couple of Sportsman 400s (my brother's bike of choice) for $50 on eBay.

Oh yea, and can any of you explain why the 97 Scrambler Output Shaft is $219, and the 97 Magnum 425 is $150?? They look identical from the poor pictures and schematics available on the web??