Hi every1, I got a Phoenix 200 for my wife and she rode it for 20 minutes and then I took it in the woods for 15 minutes and tore it up. Had to back all the way back out of the woods cause it was stuck in reverse. To make a long story short, she is pppppppi$$ed off. Now I have the tranny apart and have bought a new shift fork and shift ratchet but I can't seem to figure out how to get the gears off to change the shift ratchet, I don't c any.kind of clip holding the gear on but the repair manual says remove the circlip I'm so confused, I'm gonna b in the doghouse if I don't get it fixed for her. Any ideas would be appreciated. Thanks

 

See if this parts breakdown helps.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

I noticed that it says that parts fiche is for a 2006 but mine is a 2005. I'm gonna try to post a pic of what mine looks like cause I have studied the fiche extensively and it almost looks like mine is different, absolutely do not see a shaft collar or a circlip.

 

Here's your 2005 model.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Well I can't seem to figure out how to put my pics of my transmission shaft assembly on here, man I usually don't have problems figuring things out. Anyways, there does look like there is a circlip on there but it looks like the collar shaft is hanging over the top of it, there is a little gap down in there but no room to actually get anything down in there to get it out. Don't know if the collar shaft is supposed to slide back or what. This is the first time I've ever worked on a polaris transmission and it definitely has me stumped

 

To be honest with you I can't remember myself on the collar,but either the collar slides out of the way or the circlip is removed over it.

 

I just uploaded pics of the trans shaft into my photos. I tried to slide the collar, no success, I tried to stick a little tiny flat head screwdriver into the gap to cnif I felt an end but not enough room. I almost just ordered all new pieces but the total amount is over $300 and I really don't need every piece. I already have the new ratchet assembly cause the edges were wore and a new shift fork cause there was play in between the 2, just can't figure out how to get the dang thing apart. I had to take the whole rear end off the atv just to get the trans cover off, why do they have to make this so difficult?

 

I guess when I get home from work tomorrow ill take a closer look at it and c what I can figure out.

 

Just thinking out loud again,but seems like the bushing was supposed to remain in the engine case. If it came out with the shaft,a little heat,plus a cloth round it to keep if from being scored up and it should be able to be twisted off with vice grips. See if you can post the pics tonight or tomorrow and maybe it'll jog my memory.

 

I tried to post pics in this thread and it wants a web address. I did post pics of it in my photo album if that helps any. Gonna try the heat thing tomorrow and c if anything moves. Thanks for all ur input so far.