I need to remove the gearcase/ trans from my 94 sport 400L. I have a manual but just wanted to check here to see if anybody has done this. Anything I should be careful of or look at for. Anything to make it easier.....

Thanks

 

It is pretty simple, just take you time, and remember where everything goes(or take notes if your memory is bad). I can kinda outline it for you.....just ask questions if you have trouble in the middle of the operation.

First, remove the link from your chain, and take the chain loose from the gearbox. Next, remove your bottom skidplate. There should be a bolt that holds tension from the gearbox to the frame, and also a main bolt that holds the gearbox into the frame supports(remove the bolt). Next, remove your seat, and airbox. This allows access to the top of the gearbox. Remove the shift linkage from the top of the gearbox, to allow the box to be removed. Next, remove your clutch cover. Remove belt. Remove your driven(back) clutch. Remove drive clutch(front)....with a clutch puller. Remove the back clutch cover. Remove the swing arm bolt that goes through the frame into the gearbox. On the other side(brake), remove the brake components, and remove the swing arm bolt on this side. Remove the swing arm(once loose)......and remove your gear box.



This process can be done with only one swing arm bolt removed, but I think it is faster, and easier to just remove them both.

 

Thanks for the step by step...why is it necessary to remove the clutches? Just curious. Do I need to mark them and reinstall them in
the same position as they were taken off? Sounds like a lot just to replace a motot mount bushing, but needs to be done.

 

yeah you pretty much have to remove them......you might get by with only removing the back one.....and trying to get the swing arm bolt out.......


The key is that the swing arm bolts are kinda hidden........and they go into the gearcase for support.....

 

Thanks again...Do I need to mark the clutches and reinstall them in
the same position as they were taken off?

 

no....you just put them back on.......they don't need to be marked......


You machine is an older year......don't be afraid to tear into it.....we all know about them......!!!

 

Bradracer18

Thanks for the help. I have it pretty much torn apart as it is so I figured I might as well change the mount now.

 

Yep.....probably not a bad idea. If you do take the swing arm bolts out, its probably not a bad idea to change the swing arm bushings, and the little orange washers too....this is pretty cheap. I'd change my gearbox oil too.....or atleast drain it when the transmission is out....and you can fill it when its back in the quad......

 

I was able to get my TB250 box out with just loosening the swingarm bolts enough to getem out of the gearcase pockets. good luck.

 

got a digital camera? take pics as you disassemble and then you can see how the pieces went when you put it back together. i use mine all the time now for repairs.