[zr-man]

I broke a reverse gear & it ended up taking a small chunk out of the case, not the cover. Is a standard non-reverse case the same as one with reverse? I know the covers are different but I was hoping the case's were the same. Thanks in advance for the help.

 

[pvwheeler]

I am 99% sure they are the same.I used the same back piece on my zr when i added reverse...
Steve

 

[snow800]

I broke a reverse gear & it ended up taking a small chunk out of the case, not the cover. Is a standard non-reverse case the same as one with reverse? I know the covers are different but I was hoping the case's were the same. Thanks in advance for the help.

Yep same inner case

 

[zr-man]

cool. Thanks for the help!!

 

[zr-man]

okay, so this might be stupid (or lack of reverse dropcase knowledge), But how do I get the bottom gears out? It looks like the retainer for the shaft extension has a allen key style built into it. If this is the case it would be one big hex key. Any info is great. I appreciate all you input!

 

[rokntroll]

Right, 1/2 inch allen wrench.

 

[109jb]

Go to the hardware store and get a coupling nut for 5/16" threads. This will have a 1/2" hex and then you can just use a 1/2" wrench on it.

 

[snow800]

okay, so this might be stupid (or lack of reverse dropcase knowledge), But how do I get the bottom gears out? It looks like the retainer for the shaft extension has a allen key style built into it. If this is the case it would be one big hex key. Any info is great. I appreciate all you input!

I have cut 1 inch off a craftsman 1/2 inch chisel in a pinch, Then you can stick the piece of chisel in the reverse adapter and use a box end 1/2 wrench or a 1/2 inch socket to get it off, Larger pipe wrench will work also, but be careful you don't booger up the end
Mike

 

[zr-man]

109jb, I went & got the 5/16" coupling nut & it is too small. It is like 2 or 3 sizes to small. Looks like I will have to go back out & just buy the big allen wrenches

 

[zr-man]

I also tried a 1/2" chisel & that didn't work.

 

[109jb]

109jb, I went & got the 5/16" coupling nut & it is too small. It is like 2 or 3 sizes to small. Looks like I will have to go back out & just buy the big allen wrenches

Did you get one with 5/16" thread or a 5/16" hex. A 5/16 THREAD will be a 1/2" hex on the outside.

 

[zr-man]

it did say 5/16 thread on the outside of the plastic. I am gonna try to find a big allen head tomorrow as Lowe's tool dept stinks. In all the manuals it shows a cap screw holding this in & in the pictures they show a long socket going throught the retainer, but that seems to be impossible with the set-up I have.

 

[blasikov]

You have the reverse kit. Factory has the shorter spring retainer and a bolt.

Be aware that you also need to transfer the bolt from the old inside case half that holds the idler gear rod.

 

[snow800]

I also tried a 1/2" chisel & that didn't work.

You have to cut the chisel, the rounded end at the top won't go in.

I use a 1/2 inch chisel piece every time I put one together.
Mike

 

[mudstang4x4]

I have a question my zl 800 slips out of gear when im going down the trail 40 to 50 mph if i let off the gas you can feel the gears dropping back in and you can keep going

 

[ejowrench]

I have a question my zl 800 slips out of gear when im going down the trail 40 to 50 mph if i let off the gas you can feel the gears dropping back in and you can keep going

You might get away by adjusting the linkage, but you might already have damage done in the chaincase.