Reverse gears Ground can i clean up and reuse?

[mebearman]

My reverse gears are ground a little can I clean them up and use them or do I have to replace them.

1996 Polaris trail Touring

 

[mebearman]

ttt

 

[600etec]

Use them!
I had a 1998 trail touring from my uncle I fixed. It had a bad chain and some chips on the gears...someone had obviously slammed it into reverse while it was still moving(more than once). I put in a new chain, cleaned the case and parts good and reused the gears worked just fine.

 

[mjkaliszak]

Just clean up any rolled edges or burrs or galling , I don't normally just spout out something without seeing first but unless you have chunks of missing teeth or lost 50% or more of surface contact area ... you should be fine.

 

[xcr440]

The key is the spring, if that is weak, it could cause them to not stay tight and slip. Once they start slipping and grinding, it will keep doing it until that spring is replaced.

 

[mebearman]

Which spring I did clean them up an it still keeps grinding. I have adjusted it every way that i can. I had the shift fork knobs welded and ground round again but it still grinds in reverse. HHHHHHHHEEEEEEELLLLLPPPPP

 

[mebearman]

In my opinion theres not enought throw of the shift fork otherwise I cannot see a reason for the gears not to completely mesh together.

 

[mebearman]

ttt

 

[mebearman]

ttt

 

[xcr440]

Check the spring behind the main drive gear, that is supposed to keep the two bigger gears together, #37 in this diagram.

 

[mebearman]

#37 is the spring that keeps the 2 reverse gears apart. When you pull the lever that spring collapses and allows that gear to slide and make contact with each other and then you have reverse. These 2 gears dont mesh enough. Cable is good Fork is good. I would like to see the arm for the fork move another inch to get more contact of the gears. Any idea what else might be wrong or someone give me a cll to discuss because I am out of options.

Thanks in advance
Harry
608-994-2860

 

[xcr440]

I was confused, I thought it was grinding in forward. I had that issue once.

When you put the cover on, you have to be sure that fork goes into the slot on the gear that presses that spring when you pull the lever. Not sure what else could be going on, unless you don't have the proper spacer (#42?) on those two interlocking smaller gears, which may not let the reverse gear get far enough to them. I know when it is not in reverse, that bigger gear barely misses the smaller gear.

 

[mebearman]

Spacers are there and appear to be correct they are both the same. I just dont think that the fork moves the lower gear in far enough and I have adjusted the cable as much as I thought I could. It takes a lot of pressure it takes to move the lever on the outer case by hand. I would think that it would move easier.

 

[xcr440]

It will be very difficult to move the fork by just prying on it on the cover, using the handle with the linkage is the easiest way. I'd say your spring is doing its job then.