I've got a 1996 Sportsman 500 IRS. Its got about 4000 miles on it and I'm starting to have some tranny problems. When its in low and you get on the gas there is a slipping or almost grinding noise coming from the transmission. Its definatley not the belt its something internal. I've rebuilt everything else on the bike but I know very little about how this tranny works. I know there some chains inside the case but i'm at a lose. Any help would be great

 

Did you check all your CV and universal joints....There are alot of them on the older Sportsman and the noise might be comming from there!!!........Caper.....

 

Yea its coming from the back. and the inner and outer u-joints are all good. It really sounds like the something in the tranny is trying to grab almost like a gear or something. I really have no idea. I don't know if this makes any difference but if you put a lot of wait on the rear rack it does it sooner. Do you have any idea what wears out in the transmissions? Its a Gen IV from what i've been told and is it possible to rebuild? Thanks

matt

 

You are correct... there are 2 chains inside the "gearcase" as it is respectfully refered to. These chains are called a "Silent chain" with time and use this chain will stretch and wear. This happens from free spinning tires and jaring them back to a slower speed. Whoops, jumps, and even slamming brakes on too hard will cause this. When this chain stretches to much it will begin to slip around the shaft input and the 33 tooth gear or the other will slip around driveshaft center and the 60 tooth sprocket. Hope this helps with anything

 

yea thats exactly what I'm being told? Is is a real pain to change or have you ever messed with it? I really appreciate the help.

matt

 

Its not hard to do. GET A SERVICE MANUAL! Its worth it. I changed a silent (reverse) chain on a 98 SP 500. While your at it look at the seals and bearings. The 98 SP 500 had about 2" of mud in the tranny so I wonder why parts were failing? He had broken the vent line off, so in came the mud!

 

THanks for the help.