Well I got my 650 back form the dealer after they replaced the complete front differential. Well I was relived to find out the repairs are all covered under the warrantee. By the looks of it I really would have hated to come out of pocket on this repair. And I gotta tell ya they even had to replace the cases due to the damage. All I can say it wasn't a pretty sight...Rob

 

How did it happen?

 

Ok as far as how it happened, I was down at Wiane National forest rite at the start of your day we had JUST gotten on the main trail and I was in 4WD when I took a small jump about 2 foot high maybe, and as soon as I came down there was a god awful noise coming from the front end. I knew as soon as it happened what just took place.

Well looking at the failed parts list it consisted of :

A crap load of shims
both sides of the case
a bunch of bearings and seals
ring
and pinion

What I assume happened: the pinion let loose first and while riding it out the fragments of the gear took everything else out. I did call my dealer before riding it out to ask them what I can do to minimize the damage, well they weren't much help but I had to ask. Well it took a month for me to get my quad back the only thing I can find that I don't like is the diff lock seems stiff now but im going give it some time to loosen up...Rob

 

Let everything break in for a while and then maybe try a different oil in the front diff. I have seen posts here that different oils can make a substantial difference in the pull tension of the diff. lock. Check to see what nyroc runs he seems to have experimented with this quite a bit.