Very true, CamInuvik. I fixed the recoil and now am back to the same issues with the reverse, so ill get the new cable and hope that helps out but still if its the cable that would mean that the problem is adjustment.
Ill explain what happens when i shift it in to reverse. I let the sled warm up and reach a nice idel, then i shift it into reverse and it engages fine, then when i throttle up to engage the primary clutch and the jackshaft gets power i get a grinding noise from the chaincase, then if shift back to forward, i have to go past the primary clutch engagement point once for it to shift back into forward. I think that is werid, I know i can run it fine going forward with out a problem.
It still sounds to me like the sliding gear isn't messhing with the small gear in the center of the chain case. When mine was out of adjustment. I'd put it in reverse bring the rpm up till the clutch grabs and it would grind the gears. Then I'd flip the lever back to forward and sometimes it would take a couple blips of the throttle for the sliding gear to pop back over and the track to spin forward.
I'll try to measure the amount of cable movement there is on my setup when I shift it to reverse. This will give you and idea as to how much slack has to be out of it for gear engagement
do you have a digital camera? if so, post a picture of the chaincase exposed. ALSO, make sure you check the bottom gear bearing, if it has any play, REPLACE IT. it will cause slack while in reverse, but not as much in forward
alot of XLT's seem to have this problem, my friend and his cousin (my friend has a 94 and his cuz has a 93). I hear it alot at the polaris dealer also. good thing mym moms sled hasnt had that happen...yet.
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