OK, I just traded my bastard Sport off on a 95 Scrambler 4X4. The tranny on the Scrambler is shot - I've already pulled it apart and all the bearings inside are trashed - also the buttons are gone on the primary clutch and the ramp & buttons on the secondary clutch are trashed.

#1 - What can I do to the tranny other than replace the bearings?

#2 - Will a Hi/Lo tranny bolt in? (I know the shifter would have to be replaced) And what will it do to the overall performance of the bike?

#3 - What are your suggestions for clutch mods since both need repair?? What gives the most "bang" for the buck?

 

1. Replace the chain and check the gears for wear. Replace all the seals. Clean all the parst well. Check the play in the reverse gear when the shift fork is in reverse. The reverse gears need to be shimmed sometimes when they get older to hold reverse in gear.

2. I know the HI/LOW tranny can be put in. At least two guys on here have done it. You need to look at some old post for it. I think you have to run the tire size that the quad it came out of ran for the 4x4.

3. Get a roller action secondary. I know I keep preaching this but they are worth the money.

 

It will be cheaper to find a hi-lo tranny and put it in than rebuilding one.As you know the parts are out ragous on these things.Any of the old chain style 4x4 trannys should work. Let us know what you do. Brad

 

OK, so I've been looking at the roller action secondary's - what I don't fully understand is the different angles for the helix, and why some have 2 different angles vs. the one. Is the 40* helix the best for "all round" or would something else be?

The more I look at the primary clutch, I think it is pretty much junked - there is a lot of wear errosion in there and I just don't think it would be safe. Probably be best to find something off Ebay, although I do have an old one off a TB250 that could be rebuilt and used?

I think I'm just going to rebuild the tranny - all new bearings and seals (including reverse needle bearing) is only about $100, and the chain & gears all look good, so why gamble on someone's used tranny?