Chain Case Issue

[DJ Hennessy]

2006 Apex, I've torn this thing apart a few times now and drawing a blank on this... I forgot to tighten the nut on the tension bolt for the chain and took it out for a ride, 30kms in... Worst sound ever and had to get picked up by the rescue trailer! Realized what I did, but because I had to limp it back to a road, I'm noticing some serious grooves I think I wore into the forward gear. Put it all back together tonight and went to put into reverse and it moved maybe an 1nch... I didn't even try forward because I didn't want to screw it up more. Wondering if maybe I now had the tension on the chain too tight? Also, just to make sure I'm doing it right, the forks on the reverse arms are to drop into the gear slot right? Not from the bottom...

I'm thinking with the grooves in the forward gear I should likely replace it, worried that the if I get this thing moving again, the chain could just slip a tooth possibly???

 

[steiner]

Turn the secondary by hand to engage in forward. You will feel or hear bad things if its screwed. Chain tension should be finger tight then back off 1/2 a turn.
There is an obvious groove in the gear were the shift fork slides into.

 

[Redbeard]

x2 with Steiner.

The shift fork engages the groove (red arrow) as the outer chaincase cover slides on.

 

[snowbiscuit]

Its very common for reverse linkage to be out of adjustment when working on chaincase on the older Apexs and will lockup like you mentioned in reverse. Put it in forward and get back end up so you can turn secondary by hand. Good chance it will be free and all that's needed is a reverse linkage adj

 

[Apex1958]

Turn the secondary by hand to engage in forward. You will feel or hear bad things if its screwed. Chain tension should be finger tight then back off 1/2 a turn.
There is an obvious groove in the gear were the shift fork slides into.

Back off 1/4 turn NOT 1/2

 

[DJ Hennessy]

The groove I knew about, just thought maybe I was dropping the forks in wrong into it, turns out all was good. Too tight on the tensioner I think, got it moving tonight on the lift by turning by hand like steiner said and then turn it on to try with throttle. Was smooth in forward movement and then reverse, but when I went back to forward it made a pretty good snap sound... Thinking the wear on the forward sprocket from the chain being so loose while trying to get it off the trail allowed some slack in the chain. Have ordered a new forward sprocket since the old one looks like it has almost serrated teeth on it, and hoping the chain will be all good and not weakened at all by this. Can't see how the linkage would've moved though???

 

[DJ Hennessy]

Its very common for reverse linkage to be out of adjustment when working on chaincase on the older Apexs and will lockup like you mentioned in reverse. Put it in forward and get back end up so you can turn secondary by hand. Good chance it will be free and all that's needed is a reverse linkage adj

If I need it to pull the out more, would I spread the linkage further or tighter?

 

[snowbiscuit]

Its been a while since making adjustment....this should help http://ty4stroke.com/threads/apex-chaincase-reverse.80183/

 

[03RX1-ER-LE]

When I purchased my 09 apex last March with only 2k miles on it, at times it would grind backing up with a load on it (ie slight incline). I did a very minor adjustment to the linkage following the manual and all is good now.