I have a 00 400 Scrambler, 4x4. I came down a little hard on a double today, and broke the chain. On it's way out, the chain took a chunk out of the transmission case. Has anybody replaced one? How much? Used/New? How hard is it to get out and replace. I typically do this type of thing myself. I've just never had an ATV transmission out, or apart. Let me know what you've done when this happened to you.

Thanks in advance.

 

Never broke one, but know of a few who have...Most important things if you do it yourself is to get a service manual, things have to be put back together in a certain order. Also, check, and re-check the shifter fork position/actuation, as that seems to be the biggest source of problems.
The new cases are built stronger than the old ones. Also, the new ones have attatchment points for what some call a 'case saver' which basically is a sacrificial part that goes between the sprocket and the case, to prevent the chain from wadding up around the sprocket, and cracking the case. They take the abuse instead of the case, and are designed to break instead of the case if that happens. I don't think the new case half comes with it, you will have to buy it seperate, which I strongly recommend you do.

Farmr

 

RPatten,

I have one in great shape. It came out of a 01 Scrambler 500 4x4 but will work perfect with the 400. Let me know if you are interested in it.

Thanks
Scott
RSJohnsn@webrise.net

 

like farmr says..GET YOURSELF A MANUAL(if you dont already have one)!!!

I just took my tranny out of my 2001 scrambler...if you want to get started,I found out (the hard way without a manual... I have already ordered one for reassemly!!!) you must remove the front driveshaft,secondary clutch,primary clutch...(you need a puller for the prmary clutch) you need to pull the primary clutch off in order to completly remove the belt cover,you also must remove the BIG 1.75" bolt holding the left side swingarm to get the tranny out....it is very tricky ..I pulled mine out the right side?? GOOD LUCK !!! keep us updated!!!


Is is possable to take it off and have it welded???
I also just broke my scrambler tranny!!!!!
Thats what i planned on doing with mine utill I noticed where it
broke (right in front of the sprocket,through two bolt holes and across one bearing surface!!![img]i/expressions/face-icon-small-mad.gif[/img][img]i/expressions/face-icon-small-blush.gif[/img][img]i/expressions/face-icon-small-smile.gif[/img]


Thanks
Dave

 

Well the old crapy scrambler tranny arises again.I (HAD) a 00 400 4x4 and guess what happend to it.The tranny cracked on two hours of riding.i took it in for warranty and it was 900$ worth of warranty work(canadian).about a year later it cracked again.thats twice its cracked in a year,so i found a used casing left side i got lucky.after that i sold it.no more polaris for this boy.ONE QUESTION,DOES THE WELDING HELP,WHAT KIND OF WELD DO YOU NEED AND WHERE CAN YOU GET IT DONE?

 

Locomofo,

Thanks for the info. Is the swingarm bolt 1.75". I suspect I'll need to get a socket and wrench to get that loosened up. I've got a clutch puller so I should be OK there. I've got a few questions.

1)How did you get the front driveshaft off?
2)You left the engine in, right?
3)Did you take your trans apart yet? I'm not too worried about getting it out, but am concerned about splitting the case, and reassembly of all of the parts inside the trans.
4) Where can I get a manual? The last time I looked, Clymer and Haynes only had them through 97 for the Scramblers.

Thanks,

-r

 

Hey rpatten
answers to q's

1. I removed 4 bolts holding front differential,slid it forward
2.I remved all bolts/nuts holding engine on lifted it about 2"
it was still very tight!!!!
3.I have not cracked the case yet!!!I am waiting to find a used case!!!!
......500 scr put it on e-bay......
4.go on to e- bay type in "scrambler manual"...tons of emm(I got mine for about 26.00 delivered)

I have a manual coming(probably be here wed) maybe I could scan and send you the part on splitting the case & reassembly???

Is your case weldable??? a local welder should be able to weld it....
unless you are missing big pieces???

Thanks
Dave

 

sorry I forgot one... yes it is a 1 3/4 socket....I could only find a socket with a 1" drive so I had to buy an adapter also...(to fit on 3/4" drive)
Keep us updated!!!!!!

Thanks
Dave [img]i/expressions/face-icon-small-happy.gif[/img]

 

OK Guys,

I'm sure all of you will be happy to find this out. Polaris updated the Xplorer and Scrambler right hand transmission cases for 2002. I ordered one for my Xplorer 400 and got it in about a week ago. It is extremely beefy around the countershaft area compared to before. You can go to www.partsland.com to check it out. They also designed a chain guide that you have to order separately, and it bolts to the new case half. This new chain guide will not work with the older design. If you do order a new right hand case half, it will mate perfectly to your older designed left hand side. Remember, you will need to order 2 bushings and one thrust washer for the pinion and ring gear. The chain guide is about $7. You might want to order the bolt that holds it in place as well.

Waylan

 

Waylan's da man!!!!!!