I have personally seen 3 busted trans cases, one caused by a failure of the brackets and the other 2 caused by the cheap plastic trans guard. This is easy to prevent and will save you a LOT of money and down time.

First, go get the updated transmission brackets if you don't already have them. These replace the thin cheap brackets that might as well be made out of tin. I think these came stock on the 2001 or 2002 models, ask your dealer.

Second, get rid of the cheap plastic transmission guard. When the chain snaps, it will go through that thing like its not even there. Its very easy to fabricate a piece of metal to fit exactly like the stock guard. I've probably snapped a dozen chains in the last 3 years, but I've never lost a case even though there are plenty of dents in my homemade guard.

 

I suffer from what's behind door number 2.

Landed a jump. Chain broke. Cheap plastic piece broke. Transmission case cracked. I'm assuming in that order.

After I spend $300 on a new case, I'd like to keep it from happening again.

Could you send / post a picture of your homemade guard. What thickness of steel did you use, etc. I can make one, just want to learn from your experience.

Thanks in advance.

-r

 

The easiest way to do it would probably be to go to Lowe's and buy a piece of angle iron that already has the holes cut in it. They sell pieces already bent at the 90 degree angle you need, all you have to do is cut about 6 inches of it off and mount it so that it covers all the way from the bottom to the top of the case then bolt it on.

Here's one I fabbed out of a piece of metal, but buying the angle iron with the holes already in it will be much easier to make than this one.
Guard

 

Polaris finally got smart and makes a guard that works on the same principal as your home-made one. However, it only fits the newest style tranny cases. Great idea for the older style.

Farmr

 

HPD performance makes a chain tensioner. You remove the plastic guide from below your swingarm and install the tensioner there. It does require a little drilling and tapping but they supply you with everything you need and the directions are pretty good. This will allow you to run an inch to an inch and a half or so more slack in your chain.