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Discussion Starter #1
Got an 02 500HO that has stripped out splines on axles/trans shaft. Thinking cheaper to replace trans with good used, but not sure what years/models will interchange. Mine has EBS - is it a trans function or handled somewhere else on the bike? Is there a way to tell if a trans is EBS compatible by looking at it? Thanks for any help anyone can offer this SW Michigan newbie!!
 

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Welcome to the board!:med:
 

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Welcome to the forums!
 

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200o thru early 2004 should be the same gear and splines. EBS or non, that is all in the clutches.
It's not a cheap piece to buy new, beside you should replace the silent chain plus the center drive gear(small one).
Look online for the cheapest parts, sometimes your dealer will work with you on price.
 

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Discussion Starter #6
Trans rebuild

Is splitting the trans & replacing the gear & chain something an ATV novice (done lots of mechanicals on cars) should try or does it take a lot of tech knowledge and/or tools to set tolerances & backlash? Not afraid to open it up, just not sure what I'd be getting into!
 

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To be totally honest, it will only go back together one way-the correct way.
You really should find a manual-free download or buy a book , just for reference.
Bearing inspection and a good cleaning is what you need . About the only tools out of the ordinary is snap ring pliers and torque wrench-for the case bolts,puller to get the front clutch off,small tube of loctite blue, to put on the suspension and mount bolts.
Anything else ,ask away.
 
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