ok, so i had a transmission failure on a new-to-me rzr4, at first it thought it was the intermediate pinion shaft, then when that checked out i thought maybe the clutch or input shaft was broken.

so i pull the trans and cracked it open. the first thing i notices was the trans oil was pretty grey, so maybe water contamination then i bunch of bearing started coming out. so i dig in and find out the shift color is all janked up and the bearings were all from there. i also figure out there’s a large circlip that has been totally munched up.

thankfully all the gears look great, and even the actual bearings look and feel great, but then i go to order new parts and i notice on the diagram that there should be TWO circlips for that shift collar, but according to the carnage left in the case there was clearly only one circlip to begin with!!?!?

so i ask the PO if he ever had it rebuilt, or if the original owner ever had it rebuilt that he knows of…he says no. not sure i believe him but if he’s correct then wtf? has anyone ever heard of this happening from the factory? could this RZR really have survived 3500 miles with it missing? it did seem pretty normal to me until it failed and i have logged a few hundred miles in an 800 rzr4.

also while i have everything out, anyone have some recommendations of any other parts i should fix/replace?

ok, so i had a transmission failure on a new-to-me rzr4, at first it thought it was the intermediate pinion shaft, then when that checked out i thought maybe the clutch or input shaft was broken.

so i pull the trans and cracked it open. the first thing i notices was the trans oil was pretty grey, so maybe water contamination then i bunch of bearing started coming out. so i dig in and find out the shift color is all janked up and the bearings were all from there. i also figure out there’s a large circlip that has been totally munched up.

thankfully all the gears look great, and even the actual bearings look and feel great, but then i go to order new parts and i notice on the diagram that there should be TWO circlips for that shift collar, but according to the carnage left in the case there was clearly only one circlip to begin with!!?!?

so i ask the PO if he ever had it rebuilt, or if the original owner ever had it rebuilt that he knows of…he says no. not sure i believe him but if he’s correct then wtf? has anyone ever heard of this happening from the factory? could this RZR really have survived 3500 miles with it missing? it did seem pretty normal to me until it failed and i have logged a few hundred miles in an 800 rzr4.

also while i have everything out, anyone have some recommendations of any other parts i should fix/replace?