What is a good way to remove the gear from the counter balancer. I tried a gear puller but I messed up the end of the shaft a little, might be able to save it if we can get the threads cleaned up. I don't have a hydraulic press or any kind of equipment like that. The reason why I need to get the gear off is so I can replace the bearing. I really thought a gear puller would remove it, but it started expanding the end of the shaft. If I can't salvage the counter balancer, What would my options be to replace it and where would be my best bet to purchase one?

 

it is recommended that you don't attempt to replace the bearings on these things, but that's from Polaris!

You could try Ebay for a second hand one (usually some on there from quads where the piston has seized and the counterbalancer is fine. Or you could try local machine shops and ask them to have a go at splitting the bearing off.

If you're intending to keep the machine for a good while, I'd just cough up for a new one... you know it should last then!

 

PS I just looked at your pictures... I hope you're going to replace the piston with a Wiseco to avoid that piston breaking again!

 

That piston is the whole reason why my motor is apart. I am going to get the top end redone, possibly even a port job. I don't want to take any chances with pieces of that piston being in any of the bearings and locking up the bottom end after investing time and money into the top end. I know Polaris doesn't recommend rebuilding the counter balancer, probably because they charge about $400 for a replacement assembly.

 

Unless your crankcase has split, there should be no bits of piston anywhere near the counterbalancer bearings... assuming that's why you're replacing those. If counterbalancer case is OK, then I'd just rebuild it using the original counterbalancer bearings if they still feel OK!

 

I had to replace the counter balance in my 94 sport 400L. It broke off on both ends (at the impeller and at the oil pump) No clue how that happened. Was going to try and salvage the gear but couldnt get it off for the life of me. I ended up getting a used one from ss2wheel for $175 with a new gear and new bearings. Here is their info if you still need it. [Call Shawn or Jenn @ (217)543-3505, Email ss2wheel@consolidated.net] I have seen them on ebay as low as $30. But there werent any at the time i needed it.

 

The gear should be pressed off and has to be pressed back on. Dont forget to mark the gear and the balancer before you do this.
I do believe RCR has re-man balancers in stock.

 

I used a axle puller (slide hammer) to get mine out. Pressed the gear off and replaced the bearing (common item from bearing supply house). I used the single hook in the set. I worked it around the bearing, holding it in place with a screwdriver. But, my gear came out fairly easy and the inner bearing was what I had trouble with. Good luck.