Polaris Trail Boss Transmission repair

[@jpc42480]

Great video, just what I needed to get my trailblazer back on the trail, ended up being the exact same part numbers. Thank You for the awesome video..

[@LonnieJohnson1]

Cool!! Thanks.

[@chevy79bu]

Just rebuilt mine, your video was a great tool to see what I was getting into. Small side tip, I was able to find a perfect match O Ring in an automotive HVAC O ring Kit I had.

[@LonnieJohnson1]

Cool! Thanks for the info

[@dadlills4372]

Hey Lonnie I know this an old video but I just tackled my trailboss 330. Couldn't have done it without you. 👌. Turns out the ring clip came off the reverse gear. A very talented mechanic/welder I know made sure that it would never happen again lol. My question is did you replace the triple lip seals on the shafts. Mine look fine but my bud is just change it. Over 100 bucks for the two ughhh. I'm ready to seal it up but holding off now he's got me second guessing lol.

[@LonnieJohnson1]

No, not at that price. It should be find if it doesn't look damaged, and if your doing the job yourself you don't have to pay for the cost of labor.

[@taztaz8380]

Great video, do you know if 2013 trail boss 330 same transmission

[@LonnieJohnson1]

Thanks, and it looks like the same transmission. Check out Ronnies mail order and compare them. They look the same to me.

[@josephhammer4103]

At 12:24 the thing you pointed at snapped clean off and also broke the sprocket. I’m curious as to what part that would be so I can order a replacement. Thanks

[@LonnieJohnson1]

It shows that it has been discontinued but I found one on Partzilla but it's unavailable. Here is the link...CDS OUTPUT SUB ASSEMBLY 3234266

[@LonnieJohnson1]

Here is another link to look at...www.ronniesmailorder.com/oemparts/a/pol/503561b9f8700236841121b8/drive-train-main-gearcase-internal

[@josephhammer4103]

Thanks man 🙏🏽

[@LonnieJohnson1]

Your welcome, and I know that's not what you wanted to hear. I also had no idea.

[@brannambriley2211]

I've got a 93 trail boss my lower motor mount I'd broke causing my clutch guard to be eat on by the transmission flexing how do I fix this problem do you know?

[@LonnieJohnson1]

First you have to weld the motor mount back in place. Did it eat a hole in anything?

[@markj811]

I have a 2000 polaris trail boss 325 and when accelerating fast or pulling anything it makes a loud clicking/clunking noise. Do you think it is the silent chain in the transmission?

[@LonnieJohnson1]

Either the chain is sloppy loose or you could have some bad teeth on your front or rear sprocket. That's just a guess without looking at it. Is it coming from your transmission?

[@markj811]

@@LonnieJohnson1 it’s coming from somewhere near the back end. Maybe the chain or sprockets that drives the wheels?

[@markj811]

@@LonnieJohnson1 We started taking it apart but need to get the clutch off and then we should be able to get it out.

[@markj811]

@@LonnieJohnson1 if the teeth are shiny does that mean they are worn down and should be replaced?

[@LonnieJohnson1]

It depends on how long the teeth are and if the chain can slip over them. Look on line at a new front and rear sprocket and compare it with yours. It should also give measurements of the teeth.

[@dylannance15]

I have a 93 trail boss. Will go in reverse but won’t go forward. If I remember correctly I was riding and randomly came to a stop and I believe I heard a back fire? It’s been awhile but after coming to a stop the atv will no longer go forward.

[@LonnieJohnson1]

Will it go back in neutral?

[@coltonbocock2586]

How long do you have to wait after putting the rubber gasket on to add Transmission fluid?

[@LonnieJohnson1]

Once you get everything bolted down you should be able to add the gear oil

[@coltonbocock2586]

@@LonnieJohnson1 Ok thanks!!

[@israelalcantar8765]

I bought a polaris 2000 325 it doesn't comes with the High Low Transmission Sensor what I need to do???

[@LonnieJohnson1]

?

[@ebutuoyebutouy]

Why did the fork wear so much? Soft material? Over travel? Thanks for sharing.

[@LonnieJohnson1]

I think it was ran very low on gear oil. When I emptied the transmission it had very little in it. In the area the dip stick was in it was probably over looked.

[@NormanVereecke]

Where do you get ur parts from i have a 06 and cant find any parts

[@LonnieJohnson1]

Ronnie's Cycle

[@kalebmcmaster2160]

I have a 2006 that makes cracking and clunking noises at about 5 mph. The chain in transmission has a little slack and the shifting slide is worn not sure if this is issue though

[@kalebmcmaster2160]

Please let me know what to look for

[@LonnieJohnson1]

Put your hand on the transmission and drive slow to feel if that is where it's coming from. If so, I would remove it and look inside to see what is damaged because if you damage the wrong part, some parts are no longer available.

[@kalebmcmaster2160]

@@LonnieJohnson1 i pushed it without trans or chain on and it was the rear axle bearing

[@LonnieJohnson1]

That's a plus. The axle will be easier to fix.

[@kalebmcmaster2160]

@@LonnieJohnson1 yes but i ended up taking the trans out before😕🙃

[@ericsierra2233]

I bought a 2003 Polaris trailboss and the sprocket came off. After looking at it the previous owner welded it on but I don’t know what parts I need to fix it

[@LonnieJohnson1]

See if this link can help you. www.ronniesmailorder.com/oemparts/a/pol/5034f990f870022b94ea4dd4/gearcase

[@matthewnelson8194]

Have you ever found a video on replacement ? I can find one, thinking about welding mine due to output shaft snapping, they are like 250 new

[@braydontube684]

I haven’t taken mine apart kinda scared what could cause reverse to not work or why it’s not engaging it seems like

[@LonnieJohnson1]

Have you checked the clutch?

[@braydontube684]

@@LonnieJohnson1 there no clutch ?

[@LonnieJohnson1]

Does it move forward?

[@braydontube684]

@@LonnieJohnson1 yes and netural works but reverse dose not

[@braydontube684]

is goes it to revers shift move it to revers and give it gas and it does not move

[@andrewwitte3904]

Why put grease on the Bearings if you have fluid in the transmission?

[@LonnieJohnson1]

For when they're used for the first time.

[@letsgoBrandon4200]

I have a 91 250 Trail Boss 4 by 4 that leak bunch of oil after a long hard drive it has a clunking loud rattling noise lot of vibration not sure if it's the transmission or the motor any suggestions

[@LonnieJohnson1]

Put the wheels up on blocks to where it is stable and secure. Start it and put it in low gear, then listen for the sound or noise and feel the gear box to pin point the vibration or rattling.

[@letsgoBrandon4200]

Should the pully for the trans have any movement on it or I think a bering or seal is bad

[@LonnieJohnson1]

I would check it.

[@caseyard7143]

This also works on a 2001 scrambler 500

[@LonnieJohnson1]

Cool...thanks for the info.

[@TheCrazyR1]

Why does my transmission sprocket move but the belt drive side it locked up?

[@LonnieJohnson1]

Do you have the belt removed?

[@dallashowry5568]

I was riding mine and I shifted to drive and now it acts like it’s in low gear which it doesn’t even have and I’ll be going around 5 mph and it sounds like I’m going 25 do you know what the problem is?

[@LonnieJohnson1]

I would look at the drive belt first to see if there's an issue with it.

[@dakotalanglois]

Question will 4x4 transmission parts work I can't seem to find any of the parts I need for my polaris trail boss 250cc automatic 2stroke . I've just been keeping it in gear and starting it

[@LonnieJohnson1]

What year is your Trail Boss?

[@dakotalanglois]

@@LonnieJohnson1 it's a 1992 polaris trail boss 2x4 250cc automatic 2 stroke but the oil injector I believe doesn't work

[@LonnieJohnson1]

You can mix the oil yourself. The oil pump is unavailable but I found one for $251. Not cheap. What transmission parts do you need and I will look and see what I can find out.

[@LonnieJohnson1]

I'm looking at the parts for both ATV's and they look the same. Just let me know what part you need and I'll see if it matches.

[@dakotalanglois]

@@LonnieJohnson1 thats what I have to do I mix my gas and oil before , and as for parts for transmission I believe I need whole new thing never took it apart aha

[@aaronhenry7427]

Hey buddy my 1997 polaris scrambler 500 4x4 grinds in drive gear but is fine in reverse...what part do I order ?

[@LonnieJohnson1]

Does it grind when your driving it or when you put it in gear?

[@josecambron8278]

Hey there mine grinds while in gear and dont want to run

[@LonnieJohnson1]

Sounds like a bad gear.

[@robgouin]

Answer is silent chain is stretched

[@Ajaxaxxess]

What year trail boss are you working on? I have a 90 and it slips once in awhile at high speeds. Looks like theres no silent chain on any TB pre 94..

[@LonnieJohnson1]

2009, and if it's slipping at high speed you should check your belt unless it's a grinding noise in the transmission.

[@Ajaxaxxess]

@@LonnieJohnson1 Grinding in trans. Adjusted shift linkage and changed out fluid. hasnt done it since, fingers crossed. lol

[@LonnieJohnson1]

Cool!!

[@chrisguillen1495]

@@Ajaxaxxess what fluid would you use for a 94? I have a 300 4x4 and want to change the tranny fluid. Would some Mag1 75w-90 gear oil work?

[@markj811]

How loose should the chain be?

[@LonnieJohnson1]

It shouldn't be loose. At 2:35 you can see the chain.

[@markj811]

@@LonnieJohnson1 we could slip it off right away. Will probably order a new one

[@LonnieJohnson1]

Sounds like it was way too loose.

[@markj811]

@@LonnieJohnson1 is there anything else I should check while in the transmission. The bearings seem good.

[@LonnieJohnson1]

Do all the teeth look good?

[@bw6563]

What fluid did you fill with once done ?

[@LonnieJohnson1]

75/90 full synthetic you can also use 90/140

[@chrisschmitz1926]

What would cause my transmission to grind when going into drive

[@LonnieJohnson1]

Set the idle down and the gears shouldn't grind.

[@joeywebb4796]

Hey man where did you order your parts from do you have the link

[@LonnieJohnson1]

Ronnies.com mail order but you can type these #'s in google and find them cheaper but make sure they are not used parts. Hope this helps. (Shaft, Shift 3233679) and SHIFT-FORK 3233685

[@cesarjuarez2987]

Help me friend my polaris trailboss I stop working the reverse case will be the same

[@LonnieJohnson1]

Whats it not doing?

[@calebbloom182]

LonnieJohnson1 what was wrong what your transmission, mine will not hold itself in gear while driving. Could this cause it?

[@ttv_microwavez6285]

My trail boss 325 makes a clingy sound when in drive. Why’s the fix?

[@LonnieJohnson1]

Can you feel it in the transmission or is it the chain making the sound?

[@robgouin]

Should have replaced the Silent chain there notorious for stretching amount always the problem.

[@LonnieJohnson1]

My chain didn't look stretched but thanks

[@rockyjustus2829]

Where can I get a silent chain ?

[@3DRTY5]

that one bearing on shaft is cooked you shouldnt be able to spin them that easily

[@LonnieJohnson1]

They need to spin freely with no friction.

[@trxtech3010]

Polaris's are such goddamn junk. I can;t tell you how many I have worked on and just about every single fockin one of them have blown out A Arm bushings, Blown out handlebar bushings, Tranmission issues, all the parts ar way over priced etc. I would never ever own one.

[@LonnieJohnson1]

I will work on them but would not own one. I work on more of these 4X4 they any.

[@mariavillegas8242]

My 03 trial blasé boss drives but when I put full throttle it feels like is only going on first gear do you know why.. I really need help

[@LonnieJohnson1]

I would check the belt and clutch drive assembly to see if it's working properly.