I think I piled up my gearbox on my newly aquired 07 outlander 800 xt. I have only driven it a few kms, the atv has 5700kms on it. I am not sure what is all wrong inside yet, lots of grinding, and ALOT of play in the secondary shaft. This is a pretty big project for me, not sure if it needs rebuilding or replacing yet. Just wanted to know some tips or suggetions on how to go about doing it. Or what else I should look for or do as I will have the engine out to get at the gearbox. I started searching and reading but was just looking for some more info that I may miss.
rancidjo
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Rebuilding/Replacing gearbox, anything else?
Engine and gear box out today. Will tear it apart tomorrow to see what kind of damage.
Also plan on extending all my breather lines, maybe try and do the oil strainer, maybe check valves as soon as I find how to and if I can do them on the bench.
Anyone else have suggestions on what other little things to do seeing as I have it ripped apart this far?
Also plan on extending all my breather lines, maybe try and do the oil strainer, maybe check valves as soon as I find how to and if I can do them on the bench.
Anyone else have suggestions on what other little things to do seeing as I have it ripped apart this far?
Tough to say excactly. Started at 10 this morning and finished around 5pm. But I did lots of other stuff inbetween like go for lunch, play with my son, get his quad going, watch him ride etc. I would guess 4 working hours but I was taking my time (labeling and second guessing myself). First can-am and first engine removal from an atv. I didn't think it was too bad.
i'll try to remember to take some pics as i go. I would say if I was to do it again and went at it hard it can be done in about 2 hours if there are no problems.
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I had mentioned in your other thread to send Shane a PM, "sscard" is his user name, he might be able to hook you up with anything you need, he races them and knows a lot of guys with parts.
Do like wind said take pix it will help. It's easy to take the box apart. I'm still cleaning and pulling bearings on mine maybe in a month I'll have the funds to fix it
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the inside of your gearbox my look a little like this.
![Image]()
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WOw that is a mess in teh gearbox,i have a thread on here about tearing apart and rebuilding the gerabox.I also have videos on my youtube to help you put it together and shift all gears before it goes back together...
Split the case, but can not do anymore today (wedding anniversary). Seems like the gears have not been touched (at least not a first glance). Can see in pic that 1/3 of the fluid content of the gearbox was water. Now I have to decide if I should replace ALL the bearings in the box, I am leaning towards replacing all bearings and seals.
Attachments
Of your already this far into it its better safe than sorry I'd replace them all.since.you already have it all apart start fresh
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Yep do all the bearings and seals,i got my bearings from BRP but the seals you can get aftermarket.Check your shims to and if they are bad then replace them to.
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