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  #311  
Old 05-15-2017, 12:08 AM
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And while everything is apart this far, it's a good idea to remove the spider from the primary clutch and clean & regrease the clutch roller bearing. If it gets dirty enough it can sieze to the fixed sheave shaft and your SOL.

I have the spider tool & holding fixture if anyone in the Anchorage area would like to borrow it.
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  #312  
Old 05-20-2017, 10:59 PM
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SNWMBL SNWMBL is offline
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More on the transmission. The gears aren't aligned well and the reverse chain doesn't run completely straight. There's quite a bit of slop behind the inner most bearing on the input shaft. Had about .022-.025 play. Put a .015 shim behind the bearing which took just enough play out. The gears and chain are aligned better and not only does it spin great but it's quiet.

You can see the natural wear marks and how the gears don't align well and chain runs slightly off.



It's the input shaft that the secondary clutch is on that gets shimmed outward.


.015 shim in place


Another view(covered in Lucas additive)


Steel washer in place to keep the lower output shaft out of the case. I believe it was around .020.


Main drive chain. Links were stiff and packed(and I mean absolutely packed) with extra Polaris case sealant in between the links. My coworkers was identical. I tried everything to free it up and no luck so spent the $60 and bought a new chain.

Chains aren't suppose to do this.


You can see the links are spread apart.


New chain, the way a chain should be.



And done. Lengthy write up but I hope it helps shed light on some of the short comings of the transmission and how to fix them(as much as possible anyway).



These are interesting to me, so if anyone blows their tranny I'd like to have it before it gets thrown away. I'd really like to open a few more up.
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Last edited by SNWMBL; 12-08-2017 at 10:48 PM.
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  #313  
Old 05-23-2017, 01:35 PM
Clayton Clayton is offline
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Originally Posted by SNWMBL View Post


These are interesting to me, so if anyone blows their tranny I'd like to have it before it gets thrown away. I'd really like to open a few more up.
I'm sure you have a day job, but there are probably guys out there that would pay to have their trans gone through by someone as knowledgeable as you to the Polaris shortcomings.
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  #314  
Old 05-29-2017, 07:55 AM
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I've got a junk tranny and a junk front dif that you are most welcome to have. Thanks for sharing your findings with the rest of us. Sure wish these things were built the way they should have been to begin with.
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  #315  
Old 12-07-2017, 11:01 PM
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I'm sure you have a day job, but there are probably guys out there that would pay to have their trans gone through by someone as knowledgeable as you to the Polaris shortcomings.
I sold the Ranger a few months ago and moved on to a RZR XP4 1K. Having said that, I got a business license and LLC and can rebuild transmissions if requested.
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Old 12-08-2017, 06:37 PM
Vance in AK Vance in AK is offline
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Man I wish you could bring the pics back to this thread... It was amazing!
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