95 Polaris Scrambler broken housing
 

Hi Everyone,

Last spring, I was doing donuts in the grass when my rear chain broke on my 95 Scrambler. Finally I got around to replacing the chain. I took it out for a test run and it runs great, with the exception of the fluid leaking all over the place. Turns out, when the chain broke, it spun around and broke the housing directly above the rear drive sprocket.

My questions are:

1. - Does anyone know where I can get a housing for my 4 wheeler without paying an arm and a leg for it? When I am searching the internet, what am I searching for? (I assume it is a transmission housing, but feel free to correct me if I am wrong.)

2. - How hard is it to change the housing? It looks like I will have to take the clutch off to get to everything. Am I correct?

Thanks for everyone's advice and knowledge. I bought this used and it didn't come with a manual, so I am a little in the dark with this.

95 Polaris Scrambler broken housing
 

I did the same thing on my Xplorer 250!


Snapped because of really really really bad axle bearings.

When I get around to fixing it I'm going to remove the transmission. Flush the transmission with solvent through the hole the chain made. Then when it is clean I'm going to take it to a welder, have it fixed and also have them install a case saver. Which is a thick piece of metal that will fix this problem should it ever happen again.

95 Polaris Scrambler broken housing
 

You sound like you have a good plan...

My problem is that I don't have the metal that broke out of the housing. I think I have to replace the housing to solve the problem.

Can you explain what a case saver is?

95 Polaris Scrambler broken housing
 

The welder will just weld a plate into the hole that the chain created.

The case saver is a thick piece of steal that protects the area where the chain would hit if it broke again.

http://rittercycle.com/polaris.htm

95 Polaris Scrambler broken housing
 

Ahhhh, thanks bigike. I understand what you mean now.

Taking it to a welder to get fixed is probably going to be a lot cheaper than buying a whole new housing too.

95 Polaris Scrambler broken housing
 

I would recommend replacing the gearcase half.You have to pull the clutches but you need to do that on most anything you work on on these things.You can find a used transmission on ebay for less than what you can get a new case half for.A 1994-1997 4x4 tranny will fit.When you find one pull yours out and take it apart to inspect the internal parts for wear.Then when you get the other one take it apart and either use your parts in it or that ones parts in yours.One thing that you need to replace with new would be the silent chain inside the case.That is a given any time you split the cases.

95 Polaris Scrambler broken housing
 

Thanks for the advice. I checked eBay but I wasn't able to find anything yet.

95 Polaris Scrambler broken housing
 

when searching on ebay use chaincase , gearcase, and Transmission searches.

95 Polaris Scrambler broken housing
 

Will do. Thanks for the advice. [img]i/expressions/face-icon-small-smile.gif[/img]

95 Polaris Scrambler broken housing
 

The transmission case is aluminum, right?