Walexa, I started taking my gearcase out last night and got to the point where I have to loosen the swingarm bolt on the left side. What size is that thing? It looks like 1 3/4" but I didn't have a socket that big. It was so much easier to get everything apart than I though. Took me about an hour. Thanks for the help.

 

MGM,

Sorry about not responding sooner. I only have computer access at work, hence not replying earlier.

The swingarm bolt head is 1-3/4". If there is play in your swingarm bushings, you might want to change them out as well while you're in there. You will also need a 2" socket to disassemble the right hand swingarm pivot pin from the swingarm. Personally, I use a 3/4" drive breaker bar to remove and assemble the swingarm stuff. When you go to putting the swingarm back together, get some brake parts cleaner that "leaves no residue" and some Loctite 262 (red). Clean the internal threads and external threads perfectly clean, and spray them off with the brake parts cleaner. After they're dried, liberally apply the loctite, assemble, and tighten them as tight as you can get them. The loctite recommends a 24-hour complete curing time before putting the equipment into service.

Also, don't forget to remove the electronic sensors mounted on top of the of the tranny before reassembling........it even states that damage can occur if you don't. One more tip that I learned putting mine back together........Once you get the first shift shaft in, you MUST place it in the neutral position before the other one will go in. I didn't damage anything, but it took me a while to figure it out. If this is unclear, let me know. I can get my service manual and call the parts out correctly. Be sure to use the 3bond, hondabond, or yamabond putting the cases back together.

Does your transmission whine kinda loud in low range, but not at all in high range? The only bearings I didn't replace were the needle bearings, and I can't remember how loud mine used to whine in low range.

Waylan

 

Walexa, I got it apart and was going to put it back together. I couldn't get the 2 old bushing out of my old case that go to the prop shaft. I am going to have order those little parts before it will go back together right. I put it together and dissambled it about 5 times before i figured out you have to have those bushings. My silent chain seems like it is stretched also but I don't see how it would go together if it was tighter. It was fun putting the case back together and getting the shift shafts in there. You almost need three hands. My bike does whine a little in low when I get close to 20mph but all bearings are in perfect condition. My swingarm pivot bearings seem to be fine also. Does the nut on the inside of the swingarm bolt on your bike turn with the outside one? Mine would turn with the outside bolt. My case was cracked in 3 different places. So it was deffinitely time for it to be replaced.

 

MGM,

Looking at the right side case from the inside, I put the shaft to the left in first, with the silent chain already wrapped around its sprockets. Once that one is in, and put in neutral, the second one goes in nicely. The only other hard part was putting in the large gear that has the other chain running to a sprocket. Mine whines starting out in low, and just gets louder. I suspect the needle bearings are worn a little, but I'm not about to tear it back down. I'll probably try a few different lubricants in there to see if I can get it to quiet down......maybe some Lucas oil stabilizer mixed with Mobil 1 gear oil. Something with a heavier film like that might quiet it down some. I should've replaced the needle bearings, but they were $20 each, and they seemed to turn smoothly. I figured the case half came with the garloc bushings already installed, what a bummer. Oh yeah, be sure to use the hondabond to seal the recoil housing up too. I understand you've gotten water in yours before, and was curious as to whether it got in past the factory sealing, or after you had had it off.

Did you end up going with DID X-ring chain again?

While I had mine out, I tried to figure out how to make a case saver, but due to the location of the mounting holes for the plastic piece, I didn't see an easy way to mount one that would be durable. Polaris really needs to come up with something to prevent the case cracking.

Yes, the nut turns with the bolt. In case you ever change out the bushings, that nut doesn't go on tight.......it just takes up slack. It is also assembled with the Loctite 262. What kind of grease do you use on yours? I had the originals wear out using Mobil 1 synthetic grease, had some bronze ones made, and they didn't last as long as the plastic ones. I'm on my 3rd set of bushings now, and I went back with the plastic ones, and changed to Schaeffer's 238 grease. Maybe it will hold up now???

When do you get your joints back? What is your total for 2 joints/heavy duty boots? I haven't broken a joint yet, but I'm only running 26" bi-claws on front with a 1.5" lift. What lift are you running in front?

Thanks,

Waylan