Weird sound coming from chaincase when using reverse.. - Snowmobile Forum: Your #1 Snowmobile Forum

Snowweasel · 12-30-2012, 01:38 AM

I have a 1992 Polaris Indy 500 classic. It has reverse and electric start. I started it up today and took it out for the first time after being overhauled. I tried to engage the reverse and test it out, and I could hear this sound of winding/skipping teeth, the sled never moved. The reverse felt like it engaged all the way. I put it back into forward and that worked fine. So I pulled the chaincase dip stick and the metal shavings on the magnet looked normal. It started to freak me out so I brought it home and jacked up the back of the sled. I spun the secondary in forward and didn't feel anything abnormal to me. So I shifted it into reverse and spun the secondary. The reverse worked for a few seconds until the track stopped and I could hear that noise again. I proceeded to tighten the chain tensioner bolt, which had already been decently tight. Spun the track again both in forward and reverse, no noise (and track spun in reverse). Obviously this is the problem but it just feels like the tensioner is way to tight. Thoughts?

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wildman04252 · 12-30-2012, 09:20 AM

try adjusting the reverse cable adjustment.. put your chain tensioner back to where you had it and try the cabe adjustment.. I just had the same problem.

Snowweasel · 12-30-2012, 10:25 AM

Should I loosen or tighten the cable?

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wildman04252 · 12-30-2012, 07:47 PM

I would tighten the cable.. loosen the top nut a few turns and tighten the bottom nut

Snowweasel · 12-31-2012, 12:36 AM

I don't have anymore space to back the cable out to tension it more.

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Snowweasel · 12-31-2012, 11:22 AM

This morning I just jacked up the back of the sled and tried adjusting the reverse cable. Both loosening and tightening the cable didn't make any difference. It still made that terrible sound. But this time the track spun. So when there isn't any weight on the sled the reverse works, but with weight it doesn't. Also checked the dip stick. It's looking like more and more shavings are coming out. More than normal I mean. plz help, someone is coming to look at the sled Tuesday. I want to have this sorted out by then.

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Snowweasel · 01-01-2013, 05:18 PM

Ttt

And now wondering about a second problem. The sled feels like a boat when you just start off. It's not a fuel problem, jets are new (and factory) plugs look good, belt looks fine and primary clutch is very clean. The sled doesn't have a lot of power in low RPMs and when I get into the high RPMs it reaches about 50mph and won't accelerate anymore (even when at wot). Would cleaning the secondary fix this problem. And please give thoughts on the reverse problem.

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Snowweasel · 01-01-2013, 09:01 PM

I believe I just figured out what is causing my reverse to grind. (correct me if I'm wrong) in the chaincase there is a steel plate that goes on the chaincase wall on the outside of the chain opposite the small gears. My chaincase never had the holes tapped out for the screws to secure this plate, so I left it out when installing my reverse gears. So when I go into reverse (no matter how tight the chain is) it has enough space to push the chain out of the way and let that gear grind. That plate is supposed to back the chain. I have the plate, can I weld I to the aluminum in the case with a mig welder. I know u can weld steel to aluminum but I don't know what else to do.

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Snowweasel · 01-03-2013, 09:44 AM

Bump

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Snowweasel · 01-04-2013, 08:24 AM

Bump

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