How To Rebuild a Polaris RZR Transmission | Part 1

Rebuilding the transmission on your Polaris RZR is a big task, but with the right tools and know-how this job can be done at home and save you tons of money compared to taking the machine to a shop. In part 1 of this series, Charles shows how to rebuild the transmission on a Polaris RZR XP 1000, starting with removal and disassembly of the transmission. The process shown will be similar for 2014+ Polaris RZR models.

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[bobbyt]

Charles, you made that job look easy. Putting it all back in order would be intense for me. Great job!

[fordboy]

Well done. Easy to follow along with helpful pointers.

[UTVMechanic]

correction. you will possibly need more than a punch to remove the snorkel gear. after bearings shred and metal shavings build up behind the threads. causing a build up and binding effect.

[mikewillis]

Hi Charles. I buy alot from you guys & you have good videos on how to DIY. I see you are using tranny fluid the 2010 & newer XP 900 /1000 use gear oil 80w90 in the tranny.

[pipeliner]

I think that repeat bearing failure is the result of the bearing being subjected to excessive side thrust from the fact that the angle of the gear teeth are opposite of each other on that shaft instead of the same like the rest of the shafts and because of this the side thrust is being close to doubled instesd of nearly canceled out like it is on the other shafts with the gear teeth angles cut in the same direction. I still cant figure out why they went with opposite angles on that third shaft. If they choose to keep that design then they should have a dedicated thrust bearing to support the load as it has been made clear that the existing ball bearing is not up to the task... Food for thought...

[rogert]

Great video, is the reassembly video available?

[madman]

Is there meant to be a circlip behind the secondary clutch? My secondary clutch also looks different.
Thank you!

[paulgarcia]

Now I see why god didn’t make me a mechanic. All those gears giving me anxiety

[Truckman]

What is the real cause of that particular bearing to fail??? Had my 16 xp4 1000 fail at 3500 miles, rebuilt with all 12 skf bearings, 2 shafts andn2 gears polaris and right half case from super atv, 2200 miles later same bearing failed again, it is not any kind of lube issue or eveyone would be having the same problem, example have a buddy that has a 15 xp 1000 with right around 8000 miles no problem. Anyone found the real root cause of it? I am in the process of doing a failure and analysis of bearing and some measuring of the cases, I am super impressed with super atv cases in the fact its thicker then stock and contained all failed parts.
Edit: I did reuse factory left half case first time and replaced both halves with super atv second rebuild