Popping out of gear

[TURBLUE]

I’m trying to figure out why the last few rides my sled is popping out of gear. When the reverse actuator is installed the bottom piece with the spring under had a index mark. Now I can’t get that lined up with the actuator and actually has to be moved slightly to fit it in. Am I missing anything? I have the gear turned all the way. It’s almost like the actuator isn’t going full travel.

 

[PowderFalcon]

the actuator will go in slightly to the left, so you'll have to turn it clockwise to get the bolts to line up.

 

[SumpBuster]

Excell showed me how to put it back...super easy...there was a mark, and he had it at 7 o clock, went right in and bolts lined up perfectly. Hopefully that's all it is...

 

[KnappAttack]

How many miles on the top gear? When that bushing wears on the top gear, they pop out of forward gear.

 

[TURBLUE]

398 miles mountain riding. Gear oil was pretty dirty and a bit of sludge on the magnet. That oil has 6 rides.

 

[TURBLUE]

the actuator will go in slightly to the left, so you'll have to turn it clockwise to get the bolts to line up.

This is how I did it.

 

[ROCKERDAN]

it needs to have pressure CC when installing motor. CC pressure on actuator keep sliding fork in forward gear.

 

[x600c]

My sled came out of gear today. Trail riding in the throttle then nothing. .... 300mi on 22t top gear. What did you figure out?

 

[34pontiac]

Found this.

 

[TURBLUE]

To me why wouldn’t it be like the first picture when installed.

 

[34pontiac]

Not sure, but tried this way and popped in prefect for me and I didn't have to fight twisting actuator to get bolt holes to line up.

 

[lovesledding]

you have to make sure you are fully is gear before installing actuator, install your plunger and turn it as far counter clockwise that it will go. remove plunger and install with the notch at the bottom. Plug in actuator and cycle it once reverse/forward then install. The reason it pops out of gear is due to it not being fully engaged when installing. you need to make sure it is fully in gear then the problem goes away.

If you don't cycle your actuator first the bolts will not line up properly. Most people push on the actuator to line it up, but cycling your actuator makes it go on without any issues.

 

[TURBLUE]

you have to make sure you are fully is gear before installing actuator, install your plunger and turn it as far counter clockwise that it will go. remove plunger and install with the notch at the bottom. Plug in actuator and cycle it once reverse/forward then install. The reason it pops out of gear is due to it not being fully engaged when installing. you need to make sure it is fully in gear then the problem goes away.

If you don't cycle your actuator first the bolts will not line up properly. Most people push on the actuator to line it up, but cycling your actuator makes it go on without any issues.

I wondered about cycling it prior to installing it.

 

[billymx815]

you have to make sure you are fully is gear before installing actuator, install your plunger and turn it as far counter clockwise that it will go. remove plunger and install with the notch at the bottom. Plug in actuator and cycle it once reverse/forward then install. The reason it pops out of gear is due to it not being fully engaged when installing. you need to make sure it is fully in gear then the problem goes away.

If you don't cycle your actuator first the bolts will not line up properly. Most people push on the actuator to line it up, but cycling your actuator makes it go on without any issues.

Thank you Thank you Thank you.... I'm new to the Viper platform and just serviced it (Oil & Gear oil etc.) Reassembled everything and started it and clutch was free wheeling. I thought at first I had a clutch issue so pulled then and cleaned them and reassembled. Same issue, sled wouldn't engage into gear and clutch just free wheeling. Then I thought "Dam" did I snap a chain but realized that can't be because when I spin the track the brake rotor rotates. Pulled my actuator and noticed my notch had slipped towards 5-o'clock instead of 6-o'clock. Figured that was the issue so reset it and reinstalled actuator. Started sled and same issue, clutch free-wheeling and no track movement.
In one last attempt to fix this, knowing the sled was perfectly fine when I parked it into my shop, I came searching the forum for some guidance. Found your suggestion and it worked like a charm. Saved my a trip to the dealer...