My forward engagement gear was sheared off a month ago. I elected to order the parts and do the repair myself rather than have a crummy stealership do it for me. My thoughts? Rebuilding a Tb tranny isnt difficult at all. I took my time and removed all the spash shields. Then I removed the rear fender and light. Next I removed the belt cover, clutches and belt. Unfasten the master cylinder for the rear brakes, trans mounting hardware and then tilt the trans rearward to loosen the chain. Slip the chain off and then maneuver the trans out of its hole. Once out I removed all the case bolts holding the trans together and then I pryed the halves apart using a screwdriver. HAVE A GOOD SET OF C-CLIP PLIARS AVAILABLE. The c-clips are tough and elcheapos wont remove it. The toughest part was removing all the bearings and gears from the main shaft. I had access to a press that made it much easier. Use Polaris partsfish and print the pics of the trans. Trust me it helps alot during rebuilding. Press the new parts back on and then seat the bearings in the case. Assemble the trans chain and shaft/gear assembly outside the case. Then drop the whole assembly into the case half. Make sure to line up the shifter notch with the gears and then use some pliars to move the shafter arm back and forth to check engagement. Now use grey RTV and seal the entire case back up. Loctite the trans case bolts and torque em down. Assemble everything back together in reverse order and test it out.

A couple tips.....

Before you put all the bodywork back together....crank the bike up and make sure it goes in both gears.

I filled the case up with lube before I put it back in the bike. It dosent make it much heavier and it easier than filling it after its complete.

Seperate all your hardware and label stuff if you have to. Believe it or not I cant figure out which splash shield goes back to which wheel.

Go ahead and put a new belt in. Its a small price to pay.

If you plan to change springs like I did......do that too.

Finally I bought a brown HPD spring, Polaris belt, some Tusk aluminum bars and Gel grips to round it off. Now my bike rides better and the takeoff is better. The trans engages smoothly.

All is well!

Anyone doing the same repair shoot me a email if you get stuck and maybe I can help out!

 

Hey 02TrailBlazer. Great writeup [img]i/expressions/face-icon-small-smile.gif[/img]
BryceGTX