1988 bayou klf220 transmission noise, help. pulled engine out, turn front bevel gear can hear noise, sounds like in trans. Next step split case i guess. any ideas. Also fileings in oil. ouch help

 

Considering the age of your quad, I am suspecting if the excessive backlash of the front bevel gear is causing the noise in your trans. To tighten up the gap, you will have to install a correct sized shim. The spec is 0.06 to 0.13 mm for allowable backlash - hold the drive gear and move back and forth the driven gear. Replace existing shim(s) to bring the backlash within the spec. You would need a dial gauge to measure, and a defitnitely a service manual for more detailed procedure if you are not familar with this.

 

Thank you for the info, i have a manual on order. I will measure the backlash and see what i come up with. Again thanks for taking the time to reply.