Reverse gearbox removal / installation procedure ??? 07 phazer gt

[phazerwill]

In the owners service manual is says you can remove the reverse gearbox by removing fuel tank, exhaust system and pipes. I could not get my gearbox out with out hitting the engine block(even removed internal bearing in chain case). I ended up splitting the gear box in half to get out for removal. Not sure if I can get it all back together and reinstall the same way. Anybody have any insight or something I am missing. Thanks will

 

[down-rite]

In the owners service manual is says you can remove the reverse gearbox by removing fuel tank, exhaust system and pipes. I could not get my gearbox out with out hitting the engine block(even removed internal bearing in chain case). I ended up splitting the gear box in half to get out for removal. Not sure if I can get it all back together and reinstall the same way. Anybody have any insight or something I am missing. Thanks will

In the same boat- i took the long bolt that holds the motor in place out then pushed/pry the engine up enough to clear the exhaust port very frustrating.

 

[phazerwill]

Down-rite, were you able to remove the whole reverse gear box as an assembly ? Did you have to take the internal bearing in the chain case out ?? thanks for the info, frustrating is an understatement, my 07 phazer just turned 10,200 miles, I think the only thing I have not had apart is the engine (knock on wood it has been bullet proof) and it has not left me stranded yet on the trail, but I try and do a lot of preventative maintance.

 

[down-rite]

Down-rite, were you able to remove the whole reverse gear box as an assembly ? Did you have to take the internal bearing in the chain case out ?? thanks for the info, frustrating is an understatement, my 07 phazer just turned 10,200 miles, I think the only thing I have not had apart is the engine (knock on wood it has been bullet proof) and it has not left me stranded yet on the trail, but I try and do a lot of preventative maintance.

nope i took the reverse servo off then pushed the motor up enough to get the reverse gear box to just fit by the exhaust port(it was touching it if that explains how tight it was)for re- asembly im going to maybe take all the motor mount bolts out to make it a easier job - first yamaha sled hope i like it. never had a 4 stroke before-

 

[Snowmixer]

I also had this issue when removing mine. I was going to take off the right side plate anyway, so that's how I ended up removing the gearbox. Only later was I able to acquire a manual, and when I saw their technique for removing it with both sideplates still on, I thought "no way!" I did notice that in the manual, they had removed the servo/shifter assembly from the top, as well as the coolant hoses and overflow tank, which I did not do. So I can't say for sure that their technique did not work, but it did not work for me, and makes me wonder if someone wrote the manual before the technique was actually tested. Probably not the case, but it sure seemed like it!

If you do want to replace the bearing on the upper end of the chaincase while you have the gearbox out, it's fairly simple to make a puller with a large bolt, a couple washers, nuts and various sizes of tube cut to length. I used a 12" long piece of 5/8" all-thread.

 

[phazerwill]

As a follow up, upon reinstallation I removed the long bolt for the engine and also removed the upper chain case bearing for replacement and was able to put gear box in with out servo motor attached. It was very tight but doable by prying up on engine. Then put a new upper chain case bearing in. Then put the servo motor back on that front bolt is a ***. I did not remove or break coolant system which made it probably much more difficult.

Thanks guys for all the input and help. This site is great.

 

[farmerschiferl]

Once again thank you for the ones who found out the hard way, working on mine now. Wow is it a pain in the but.

Sent from my XT1650 using Tapatalk

 

[Jan Hohmann]

Hey guys, just started to rip mine apart. Looking for any videos you might have to show how to do it. Took all coolant tanks and hoses, as well as servo motor, which does work. When I shifted the dog over and tried to move fly wheel you could feel the track move, but when dog shifted over to other side, it gears moved freely and no track movement.
Looking for help. Thanks

 

[Jan Hohmann]

Once again thank you for the ones who found out the hard way, working on mine now. Wow is it a pain in the but.

Sent from my XT1650 using Tapatalk

Hey posted a note after yours, wondering how you made out