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Discussion Starter #1 (Edited)
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I have a 2015 Rzr 1K with 13.5 K miles. Yesterday I went for a ride and heard this terrible noise from the rear gear case. I found a hole in the side of the gearbox next to the shift cable. I have seen this at least one other time here. Has anyone else seen this or know what caused it? A new gearbox is about $2900 + labor. Two years ago my front transfer case went bad and had to be replaced $1600 + labor. I’m just an easy trail rider and don’t abuse my equipment and keep up on all Maint. Schedules.

Sorry the photo is sideways. The forum kept doing this and wouldn’t post it straightened. A Honda Talon my be in my future if Polaris parts keep falling apart.
 

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Probably a bad bearing. Sucks cause might as well get a whole new transaxle cause the half piece is pretty pricey.


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I like to make lemonade out of lemons :) I’ve always wanted to tear into a transmission. A friend of mine did the same thing as you. We had another friend that had an extra one so when he pulled his out I asked him if I could have it. I figured if I screwed up tearing it apart and putting it back together it wasn’t a big deal. They are way easier to take apart and fix than most people realize. There are videos on how to do it. On mine he broke the snorkel gear and put a hole in the side of the case. You can get on super atv and buy heavy duty cases. You can upgrade as much as you want with heavy duty stuff or just fix it. You could even do a gear reduction while you are in there. Just take your time and lay things out and take pictures as you go so if you get stuck you can refer to them. I wouldn’t put a used one back in cause it could happen again . I’d upgrade and build it . You can have a better transmission for the price you pay for a used one.
 

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Yes, this is a bearing failure. You might be able to repair this relatively inexpensively, but you would need to remove the transmission and split the case to know for sure. Really depends how much other debris damage there is.

Extended warranty would typically cover this as long as you had service records for it, but there is always the potential for an argument over aftermarket parts.
 

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I had a similar failure in my 900 XP years ago. It turned out to be a bad bearing. The warranty took care of it and replaced the half the case, bearing, and took care of labor (less than 1000$). Once you’re inside you should update the output shaft and replace the rest of the bearings with SKF if you plan to put another 13,000 miles on it.
 

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I have the extended warrenty with my 19 xp1 I was just curious of what it will cover with out a argument I usually do all my own repairs but if the warrenty will cover it I wont touch it but hope nothing happens to soon it's got 10 miles on it but never know with polaris. Didnt mean to jack anybody's thread if I did I know break downs suck
 

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Damn, sorry to hear that Roger. I've talked with you before and know you are pretty easy on your equipment.
I've read that the bearings and the reverse chain just plain suck on the XP's, and I always have that fear in mind. I figure at some point I'll pull the trans and replace the bearings and chain before they break...when is the question though. I've got 2800 on the machine now. Change the fluids every 15 hrs or so, if that helps or not , who knows.
 

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Damn, sorry to hear that Roger. I've talked with you before and know you are pretty easy on your equipment.
I've read that the bearings and the reverse chain just plain suck on the XP's, and I always have that fear in mind. I figure at some point I'll pull the trans and replace the bearings and chain before they break...when is the question though. I've got 2800 on the machine now. Change the fluids every 15 hrs or so, if that helps or not , who knows.
i always said keeping fluid clean helps but who knows, and btw what fluids do you use in your front and rear cases? Polaris or other? I just got a xp upgraded from 900 and I always have that fear of reverse chain and bearings also
 

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Damn, sorry to hear that Roger. I've talked with you before and know you are pretty easy on your equipment.
I've read that the bearings and the reverse chain just plain suck on the XP's, and I always have that fear in mind. I figure at some point I'll pull the trans and replace the bearings and chain before they break...when is the question though. I've got 2800 on the machine now. Change the fluids every 15 hrs or so, if that helps or not , who knows.
i always said keeping fluid clean helps but who knows, and btw what fluids do you use in your front and rear cases? Polaris or other? I just got a xp upgraded from 900 and I always have that fear of reverse chain and bearings also


I changed the transmission fluid every 500 miles on my XP 900 and had a bearing failure. The XP1000 I’d often drain and refill around every 200-250 miles and still had an upper bearing failure. Roughly 800 miles later I broke the output shaft. I never broke a reverse chain, rear axle, or even blew a belt. The Turbo drive train is a lot better.
 

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Discussion Starter #13
Well the verdict is in,
A bearing in the rear gearbox came lose and ate a hole in the gearbox. Then they found a bad rear universal joint and a bad bearing and seal in the front left axle at the transfer case. Add complete fluid change and set set of Tensor Regulator tires and we are at $7K.
 

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Ouch ! That is a bit steep it seems. Are you doing any of the work yourself ?

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Discussion Starter #18
The new gearbox is $2900 + and then labor which puts it around $3800. Then tires are about $720+ labor. Then new bearings & seals for front transfer case, new universal joint and seals for the rear + labor. Then complete fluid change throughout. Adds up quick. You have over $5k with just tranny and tires.
 

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The new gearbox is $2900 + and then labor which puts it around $3800. Then tires are about $720+ labor. Then new bearings & seals for front transfer case, new universal joint and seals for the rear + labor. Then complete fluid change throughout. Adds up quick. You have over $5k with just tranny and tires.


They charging you $500 to mount tires that you bought from them? They’re charging you to mount tires you bought from them period? You really should consider a new dealer....or performing the work yourself... could pick up a clean used tranny from AZ cycle parts for $1k, put new bearings in if you want, still under $1500, bearing and seal kit for the front diff is $200 tops, U joint is $45, new seals for the rear come with the gearbox, fluids are about $70, you could get tires already mounted on new wheels for $1200.... that’s only $3k, and you have new wheels too!


-Give it a second... it had to go to space and back first ( Sent from the lifeline that is my iPhone XS Max )
 

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The new gearbox is $2900 + and then labor which puts it around $3800. Then tires are about $720+ labor. Then new bearings & seals for front transfer case, new universal joint and seals for the rear + labor. Then complete fluid change throughout. Adds up quick. You have over $5k with just tranny and tires.
 
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