 Hey guys welcome back to titanium and garage and uh three new subscriber keep in mind i've got a bunch of videos out there from 94 to 2004 so whatever you got going on two strokes four strokes i probably got a video on it so today we're gonna tear apart a transmission on a 96 sportsman 500 i got this off the farmer said the transmission went bad on it so i'm gonna rip the rear axles out start from there pull the clutches and uh just want to let you guys know as i'm recording i'm going to just let the camera roll and when i get to parts that are a certain detail like the axles i'm going to post links i have videos that are a little more detailed on what i'm doing so that way this isn't like a 30 minute 40 minute video video um if you want to see how to take a rear axle out i got a video on that you can just click on the link um so all right uh sit back relax have a beer and enjoy the show so the story behind this is the farmer that owned this last started pulling the transmission out and he couldn't find a replacement so he started tearing bolts out um let me kind of give you a quick overview there's bolts here there's two bolts here from the swing arm or the arm that go into transmission um a couple here he's got this disconnected already like i said uh in my preview farmers tend to take good care of their machines um yeah they don't wash them too well i'm gonna nick nick name this one the cowl because it's full of cow crap but there's a bonus to this there is a uh nice newer clutch on there that's not a playlist um so let me show you what i got going on initially i first thought it might might just been the shift linkage that was uh maybe bent or not adjusted right you know shift linkages here i've actually bought a couple atvs that the guys saw the transmission was shot and all i did was adjust just the shift linkage so show you what i got going on here i took the uh the cover off the bolt cover and i started spinning the secondary right now it's a neutral just to kind of see what's going on see now this guy had taken us apart and i'm going to show you guys he did this all the wrong way he he pulled the uh the axle shaft out first you should really unbolt it from here pull it out the right way disconnect all this stuff and uh i'm going to go through that and show you how to do it the right way if you pull a transmission don't do it like this he's got axle shaft stuff there um so what i wanted to show you was if i put it in gear now and i'm going to spin the secondary there you go you heard it so there's something going on there so i'm sure the more you drove the more click click click so it's always hard to leave off where somebody started you know when you're working on somebody else's project half everything's all taken apart um if i were to do this and start from scratch i would uh you know pull the hubs off get rid of the arms move that all the way i would pull the axle shafts out first get rid of the uh the clutches and move that backing plate he's got it half disassembled i don't even know how you plan on pulling this apart i don't know he just did it backwards so hopefully this video guys helps you out so uh if you ever have to take a training apart you don't do it like this guy did so i guess what i'm going to start to do is uh i'm going to start pulling this apart get this all out of the way i'll get my clutches out of the way get my uh shifter cables disconnected and uh in order to pull this out i'll have to move the exhaust through i think i'm gonna have to pull this out only because this might hit let me pull it out and i'll disconnect the uh the brake the rear brake i'll pull that completely off get that out of the way now you wouldn't have to take that off if you didn't want to but me i just want to get it out of the way if you do just to keep uh keep track of my parts so you'll lose everything as i try to assemble as much stuff try to keep as much stuff together as i can so you know haul goes back together okay so you remember how this side had the uh the busted u-joint um what i was able to do is i left the hub on and i had to put the tire on to keep this from spinning and i took that nut out i could slide this so here let me show you what i got going on here i got this dissembled the uh rear axle shaft did some damage here so i actually have um another uh swing arm or a arm whatever you call it that's probably why this is so tight it won't even move and it's pretty hacked up uh i might end up having to replace that so i'm gonna go ahead take this off remove the spring because that's probably gonna hit anyway and uh i'm taking this off anyway all right so from here i remove the the exhaust remove the muffler um that shock that was in here i actually think that was probably uh the start of the issue the shocks the bushings were bad so i removed that and then i'll be able to pull out out of the way so my next step is i'm gonna remove this it's uh four bolts up here one two three four and that connects to the transmission right here and there's uh two bolts on this side and two bolts on the other and so you'd remove those first and then remove these uh i'm just gonna get that bracket out of the way because it'll be uh easier to slide that transmission back yeah let's see where else is there's some bolts so two here and then of course the ones here and i think there's two at the bottom let's see here there's one here you know like i said i'm uh finishing else uh somebody else's project so it's always a little tricky because uh never know where that guy stopped and started so i don't know what bolts are removed and what he didn't so so i'm gonna take this one i'm gonna remove my shift linkages and uh this thing should be about ready to pull all right so i got those two bolts up bolting under the tranny and then uh there's two bolts here and we can get this plate out of the way now um as i was separating this like i have this up in the air and the top and the bottom frame is starting to separate so just keep that in mind i've got jack stands under the frame so it doesn't drop but it's just something you should keep in mind so i'm gonna go ahead remove those two bolts and get that plate out of the way i'm going to uh remove my linkage here for the brake and then i'm gonna pull that off and i'm gonna remove my shift linkages all right i'm gonna remove the shift linkage what i do is i just got a little uh locking uh needle those pliers and i use a 10 millimeter and i'll remove that bottom bolt and then for this shift linkage over here i just disconnected it right here uh take the pin out this little guy pops out and then when i pull the transmission out i'll be able to get the rest of that off it's just another cotter pin down there and a pin that pops up and i just uh don't really feel like reaching it from here this is just easier okay so next will be the uh the brakes and uh do your clutches on the other side and uh i got the one bolt underneath here and then we're gonna have to lube this up really good down here this this shaft going in here um because that's gonna separate and then we'll pull it all back and see how she goes one last thing i forgot to mention don't forget to disconnect your speedometer cable let's just twist off and pull out all right so let me give you a quick overview of which bolts to pull you got that uh plate two bolts there you got the two bolts the four bolts there for the a arm bolts here both here same on the other side and of course uh the thing that comes down there are three bolts i believe on the bottom you've got uh one here there's two here you can see right there's two here do that they're gonna pull them three bolts and start prying on this thing and see what it does all right so you got the training pulled so if you didn't see in the camera here's the shaft that comes off the transmission and uh here's your front drive basically trying to get that out of that so i had to hold the transmission use my persuader and knock her a couple times i have one transmission so i'm ready to put the new tranny in um show you guys a little tip here so best thing to do is if you can get these really clean and then put some grease on there anyway that should slide right into that front driveshaft i'm gonna pull the speedometer cable bracket whatever you call it and put it on that training i want to do that first before installing it but we're gonna slide that bad boy in there like a like a turd on a hot tin rough all right so i got it in place i got the grease up that shaft set the slid right in now i just gotta get it to pop forward so this should uh slide right in there while i'm pushing it in so i'm using my persuader make it come in a little bit nice get her all lined up i can see her bolt they're on all the bolt holes lined up so what i'm gonna do is i'm gonna bolt these up first the bolts underneath and then i'll put that carriage on all right so it's blue oxide on there i'm gonna throw some loctite on there once i clean out the bolts just gonna get all four started so everything lines up these two and the two on the other side then i'll do the three on the bottom all right so the reason i like uh get the bolts lined up first is uh you don't have your bottom ones lined up you start tightening these down bottom ones might not line up except this seems to be sliding forward a little bit so we're just gonna hand start all the bolts to the bottom and once they're all in and everything's lined up i'm gonna tighten it all down so i do not know the torque specs off hand i'm gonna have to look them up right now i'm just gonna snug everything up i'd like to see when something goes together all right now i'll put that top plate in place we got a nice clean machine to work on i mean all right so anybody remember how that goes back on i'll do the same thing again i'll line up all four bolts so you guys what i'm doing just getting these bolts tight i need an extension or a wrench in that one ever i get in she's basically in place right now all the bolts all the transmission are in place so the rest is just the accessories it turns out i'll have to replace that shock because the pushings down there are shot this thing wiggles so yeah i'll be replacing the shocks we're replacing the axle shaft and maybe give this back rack a nice coat of paint all right so one last thing that i didn't go over and i'm not gonna go through how to do the axles i'll post the link on how to do that but there's one important thing to know the uh the axle shaft there's two different types um 96 through 98 there's a bolt on there and uh if you watch my video i'll post the link pretty quick right above the screen just shove that back in there tighten the the bolts on both sides and it clamps right in the newer style ones have a retaining ring that go right around the edge of this and you grab it and you shove it in now the part i didn't tell you because uh i didn't have that style was to pull it out it's kind of like pulling out a slight hammer grab this and just yank it out i might have to try to get a screwdriver behind here get the pop off and be careful not to damage the case here you have it guys one installed transmission i'm not going to go through uh assembling the rest of the suspension because like i said you can check that out in my other video so i'll just adjust the linkages put the brakes back on right now i'm waiting on parts so i have to get the rear axle shaft that's coming in and i've actually got that swing arm or eight arm that's all bent up um i gotta find that and replace that i got my clutches back in everything's in place i'm also replacing the uh the rear shocks because the bushings are shot so there you have it one installed train the monkey wrong with a little bit so that's the way i can show you i'm gonna go ahead put her high spin this see the axles rotating right there i think we got her adjusted perfectly before i go who wants to see me tear this case apart i'm kind of curious to see what's going on so if you don't want to see this part um thanks for watching the video but if you do i'm kind of curious what the inside of this bad boy looks like so uh stay tuned and i'm gonna rip it apart and i bet you there's gonna be a missing tooth in there or something broken chain we'll find out hey guys let me show you what i found out i got the cover off um i don't know if you guys are just as interested as i am in this kind of stuff but uh i think it's pretty cool to see how things work so what i found out is uh this uh transmission is similar to the two-stroke style transmission it's still got the dog gears the shift forks this big gear here and normally your shaft would come straight out that way this has a little added a little more added to it you've actually got another bigger gear back here you got another chain chain tensioner and which is almost maxed out this chain is really sloppy surprise it didn't fall off so what i did was i put in gear and i wanted to see what was going on and i started spinning it and i heard the click-click noise that uh i heard before and what's going on is this chain down here is actually uh almost like wanting to jump off of the gears and it binds up you can kind of see it's just it's almost falling off basically see that so when i spin this it immediately locks up it doesn't want to spin i'm granted with the cover on this it's going to spread this apart and make it tighter but yeah i got this keeps locking up so uh that's actually good because um the rest of the transmission looks good i mean there's a little wear on the teeth but i could probably buy a new chain set put this back together and have a good tyranny you said i'm sure there's probably more to it once uh you pull a gears out pull a big gear out get the other side for the uh the tyranny brake uh i'm not going to go that far at least right now you know maybe in the future i will but so hope you guys like this uh i don't know i thought it was pretty cool to tear something apart i never did before and check out what the inside looks like but hey that's just me uh if you like the video hit the like button uh please subscribe i've got uh tons of videos on whatever you got and uh hit the bell if you want notifications for my new videos that are upcoming thanks for watching