Anyone know how to remove tranny gears on '96 polaris magnum 425 4x4?

[hrc200x]

I've got the cases split and nothing falls apart like a usual tranny, I can pull and push on stuff and nothing comes out. Seems like the two shifting rods that go from outside to inside the tranny are holding it along with the shift forks and the gears they fit around. The shifting rods appear they won't pull out from the outside of the case, they gotta go in, but too many gears in the way.

[dirtface]

I have a 1994 sportsman 4x4 tranny apart right now. It took two of us to get it apart, the two shafts that the forks are on, are held in by two spring loaded pins that are wedge shaped on the ends, that go into a "v" shaped grooves in the pins that the shift forks are on. The parts aren't cheap, we had to buy one shift fork/shaft, one seal, and the one piece that the shift fork slides back and forth and it was over $200. With that chain around those tranny gears and shafts, it all has to come out in one piece. I don't own a Polaris (this is a buddies), I have worked on a good number of them, and I think they are junk. This quad is in nice shape for the year and only has a couple thousand easy miles on it. It has always been kept inside, but the suspension and alot of the pivot joints are just worn out.

[hrc200x]

I did get it apart, I think it was the bearings in the case that were holding it cause when I started pounding on the outside of the case that the shafts were stuck in stuff started falling out. Reassembly could be interesting. I agree, they are cheaply made. This magum cost me $150 so couldn't pass it up. But after a person gets it home they start seeing why it was such a good deal. Swing arm bushings bad, hole in case from chain, cv boot ripped, very front sprocket cracked in half, cracked right side chain cover, every light bulb is burnt out on it(hopfully from running without battery), missing recoil handle, starter bad, speedo missing, bent steering stem.

[dirtface]

I have drug trikes and dirtbikes home that were sitting outside in the weeds. And very little work and they are running. These few year old Polaris quads if they are left outside in the weather for any length of time, things start going to crap on them, mechanically. Also I have worked on a few that kids rode and beat the tar out of, kids aren't a good thing for them either. But for $150, I would have been tempted too. Good luck, I haven't started putting this one back together either, and I not looking forward to it neither, maybe i'm going to get ahold of you for help when I start putting this one back together.

[hrc200x]

I hope the local machine shop will have the hole in the case welded sometime this next week, as soon as that happens and the new tranny chain and countershaft seal come in it will be going back together.