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broken pinion gear in gear box of outlander 800

7.5K views 8 replies 7 participants last post by  Estes outty 800  
#1 ·
here are some pics of the pinion gear i broke thursday night at Mudstock 2011 at River Run ATV Park











this is the pinion gear that turns the output shaft that goes to the rear drive shaft and through shaft

this was in a 2009 outlander 800, the bike has 1600 miles of mud hole abuse on it

this was first ride on the bike with the new QSC primary and STM secondary, the clutches were awesome, too bad the gear box didn't hold up for the entire weekend

it was a fatigue failure, every one of the remaining teeth have a crack that starts at the root of each tooth
 
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#2 ·
You are hard on equipment brother! We had a BLAST though!
 
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#3 ·
Ouch! Did it take anything else with it?
 
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#5 ·
that was the only broken part, the ring gear had few nicks on it, but nothing compared to the pinion, brp sells the ring and pinion as set so it doesn't really matter

the cases were chewed up a little on the inside from the broken teeth getting caught between gears and the cases, but they are still good

the oil looked like silver glitter when i drained it from all of the metal floating around!
 
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#6 ·
Do you have the shop manual for the rebuild instructions? I'd like to see the procedure and clearances/preload settings. In case I ever have a cause and effect ride Lol!
 
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#7 ·
I feel your pain man... I didn't know my trans broke Thursday night (mud stock) until I fixed the prop shaft Friday.. I haven't pulled mine or tore it down yet mut my $$ is on a broke pinion gear as well.
I was tough on equipment this trip for sure.. LOL
 
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#8 ·
all the info is in the manual, there isn't much to it, you need to take a few measurements with calipers and feeler gauges, then there is a formula in the book that tells you what thickness shim to install, the shims are EXPENSIVE, i got a used gear box that i will use, it just needs the bearing replaced, i may fix mine later
 
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#9 ·
Watch that case I'll bet if it ain't cracked all the way thru it will be the next time you put the bike in a good bind been there done that
 
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