long story short bought a project for my gf to ride. While checking it over found swing arm play, then noticed them at the bushing or along that long is missing where the swing arm pivot bolt goes into the gear case and about 1/4 portions of the gear case is broken off that holds the bushing. Called Polaris, apparently this is a non serviceable part which is stupid. Ideas for riggen? Only idea I have is welding something in there. Rather not buy a side case just for that. Pictures below are good side(left) and the bad side then a gear case side on eBay. Thanks I appreciate all advice and help I can get.

 

Forgot to include, I found replaceable bushing on eBay for 2000, wondered if I could make that work. Polaris said that the gearbox’s are different on 2000 and are not interchange about. But figured I could shave the bushing down as long as the ID and OD were similar then weld it in?

 

Gear cases are different. The pivot you have fits various models from 93 to 97 models. The pivots on the later models are more of a thick washer type rather than a cup like yours is. A lot of stress on this area because of all the jumping that most Trail Blazers were subjected to.I've had the same thing happen a few times. Just my two cents on this, if the machine is in good shape other than the cases,I'd swap cases. Hard to fix something in this area enough to make it last.

 

Ahhh thank god. Although that was embarrassing, I was assuming it was part 20 on the explosion diagram lol. Yeah that’s crazy they have a about an inch of a 10 mm bolt and steel bushing as a pivot point. Would’ve been nice if they had atleast put in a zert fitting for it. Will these bushing hold up for a few years? Would like to weld it in since I race and my gf doesn’t lol. Hoping the internals are okay, I haven’t been able to drive it yet, waiting on drive belt I’ll know this weekend if gear box is any good. Just to clarify, it’s number 21 on this diagram right?

If ya don’t mind I have some other questions, I’m new to ATV world. The oil injection has been bypassed, figured mid as well leave it but want a Pros opinion on mix ratio. Also the front hood apparently became highway decor on the way home which damaged the control panel in the process. Is the panel necessary/be bypassed? Figured I’d mount ignition switch someplace else if it’s optional.

 

Oh wait, that link above must be wrong. Is it part 6 on this diagram?

 

#6 on your pivot.https://www.partzilla.com/catalog/po...c-trail-blazer Still plenty of these on ebay. Priced high to low..https://www.ebay.com/sch/?_nkw=3233024%20Polaris I'd mix 40/1 with a good brand of synthetic premix oil. Doesn't matter the brand as long as it's for motorcyles/atvs. You don't have to have a battery if you don't want to. Magneto triggered ignition. You can tie the red to red/black leading from the switch(or what's left of it) together and use the recoil start if you wish.Or run a run a toggle switch. The left control kill switch,if still intact can kill it.

 

Oh that’s awesome, you made my day! I’m ordering it now, I’m guessing that this old bushing(left side) will need a slide hammer to yank it out right, hammer in new right? I would have assumed that it would be with swing arm, damn I was panicking thinking they were non existent. Well would like to keey battery for electric start because my gf will bitch lol. Good thing is I know it ran off the start switch initially. Have a used ignition switch on the way now. As of right now I haven’t checked the recoil starter yet but doesn’t look good, cord and cover is missing which hopefully that is it. I may have named off the wrong component, the part that got damaged is neutral/gear/ low oil indicator. Once I find a manual this would be easier,

 

Heat the case up with a propane torch.This should help get the old bushing out and the new one in. Here's a 5 buck service manual.1997 Polaris Trail Blazer Service Manual PDF Download

 

Old polaris tech you are the man.thanks so much for the help. I purchased that manual as well. While putting the atv back together I’ve noticed some missing parts for the rear brake and front sprocket. The front sprocket has some side to side play when the snap ring is in. Splines are okay and Parts diagrams doesn’t show any shins but there is one on there. Figured I would shim it tight with the shin on snap ring side, any imput? Also the output shaft bearing is missing, I’m sure it’s there for a reason of snapping the output shaft but wondering if it is necessary. Figured I could snap ring/washed to hold it in place on the inside. Also the bolt to secure it on the outside is missing but the parts diagram doesn’t show that either. Damn I’m struggling with these diagrams....

 

Don't shim the front sprocket as there will be side to side play on the sprocket and shaft.Also the output shaft bearing is critical as it supports the shaft and also the brake rotor. This could be part of the reason that you had stress on the pivot area of the case that broke.https://www.partzilla.com/catalog/po...c-trail-blazer The little shim spacers behind the output bearing aren't needed.#18. Also two carriage bolts(#16) are inserted from the inside of the frame into the bearing housing. These are held on by two nuts. Also output shaft assy comes with the two seals listed. Usually the bearings get chewed up because people forget to grease them or didn't notice the fitting.