Ok so heres the deal. i got an 02 scrambler and a week ago i was riding it when out of no where i heard a couple loud clicks from the rearn end area, and i was going probably 40-45 on a frozen lake, so i went to slow down and see what it was when my rear end just locked up and i came to a skidding stop. so, i had someone pull me to my truck to bring it home, and when it is in gear, the quad will not move, and when it is in neutral it rolls but i can hear some noises from the tranny, like parts clicking around. so i brought it home and took off the cvt cover and when i tried to turn the clutch on the tranny side it would not budge. also, if the quad is jacked off the ground, and i put it in forward or reverse and turn the back wheels, they dont move, the front sprocket doesnt spin. so, i figure im gonna have to take the gearcase/tranny out becuase for some reason it seems to be seized, but i have a few questions...

-First off i used the service manual instructions to get the tranny out and i cannot get the drive clutch off(the one with the spring that grabs the belt). i got the clutch off on the tranny side but not the one that comes off the crankshaft.

-Also, does anyone have any ideas what it could be before i get the case out and split it to see whats up inside? Has anyone had this happen before? Thanks.

 

ok i saw the threads on the inside of the drive clutch so i used some threaded rod and vise grips to get the drive clutch off. But this was after i made the BIG mistake of using a gear puller to try and get it off and i ended up breaking off one of the corners pretty bad on the front of it...

 

now ur talking about some thing being seized now will the bike run....if so its not seized..........theres probley a gear in the case thats froze and wont budge.........how bad did u brake off one of the corners pretty bad on the front of it...

 

yae the bike runs fine. it was just, when it broke, you would put the quad in forward or reverse and it would just rev a little but it sounded like it was under a big load and the quad wouldnt move. So, i took off the cover for the CVT and the belt was fine and when you would rev the motor, the belt would get real tight but would not spin like normal operation, so i shut it off and went to try spin the Driven Clutch by hand and it wont budge. Also, if the bikes in gear and not running and you try to roll it, it wont move. Its like the transmission itself wont spin over inside.

 

umm ur trannys is probley shot.....so u probley gonna have to brake it down and replace some gears

 

Sounds like you had one of the chains break inside the gearcase.Not a bad job but just hope you didnt mess things up too bad.
On your primary clutch they are going for around $65 +shipping for used ones on ebay.
You cant run one broken like yours because it will throw the system out of balance.

 

ftwflh,

Just want to say it's good to have you here. Sincerely Dude.

 

ftwflh is right, sounds like you thrashed one the chains inside the tranny. its ok, i have done it too. its really not a hard job at all, as long as you didnt thrash any of the other internal gears or parts. the hardest part is getting the rest of the bike torn down,(plastics, covers,etc)

you can save your self alot of money by taking it apart yourself. then if you need parts, then you know what your really need, and not what some dealership tech tells you.

as far as the primary clutch goes, you should have read the manual to follow the proper way to remove it. now youll need a new or used one.

take your time, keep track of how things come apart, and be careful. follow the manual.

X

 

Thank you[img]i/expressions/face-icon-small-blush.gif[/img]

 

alright thanks. At least now i know what to look for when ive got the tranny on the bench. And the puller was my dads mistake[img]i/expressions/face-icon-small-shocked.gif[/img], the manual said to use the clutch puller so my dad figured a gear puller would work, bad idea.

It is a pain though seeing how much has to come apart. Not fun, very time consuming but its worth it. I never send any of my machines to get serviced at dealers or shops. Its just to much money. Id rather rip em down myself and just by the parks i need online from one of the oem parts sites.