There have been a few people getting mud into the gearbox. I had this problem also. During my compleat tear down I found where the mud was entering my gearbox. There is a sensor by the gearbox fill plug. This sensor has a o-ring around it that was chewed up and not sealing. This was letting mud and water enter the gearbox. This sensor is also magnetic and was covered in metal shavings.

Looks like Atvers quad AFTER he gets finished changing the oil.

Looks like you have taken the top off, doing some performance mods, or just maintenance?

quote:

Looks like Atvers quad AFTER he gets finished changing the oil.

I still don't have that sucker back together, I should have wrote down where the parts came from I guess.

Great info B2S !!! Any idea what the sensor is for? Besides collecting metal and letting in water...

the sensor is called a "speed sensor" i guess that it tells the ecu how many rpms the gears are turning.

i'm just going over almost everything and doing a compleat one year inspection. I have learned more about the outlander in the last week than in the last year. i have read both the service manual and engine manual cover to cover more than once. (i'm a mechnanical nurd and i have wrenches in my pocket protector)

If you pull off the sensor will the fluid come out or is it above the full level? I just changed the gearbox fluid. thanks maxdun

some fluid will seep out but not much. it is above the fill line.

i have changed the gearbox oil 10 times since it was new. i have around 2000miles. so it took a lot for my sensor to get that much junk on it.

THANKS!

quote:

Originally posted by ATVer:

quote:

Looks like Atvers quad AFTER he gets finished changing the oil.

I still don't have that sucker back together, I should have wrote down where the parts came from I guess.

Great info B2S !!! Any idea what the sensor is for? Besides collecting metal and letting in water...

Pictures would be better

You Grizz riders leave me alone!

I think that the sensor is the speed sensor. This is the sensor that was causing my
speedometer to fluctuate and the bike to cut off/on after it warmed up. Good luck
with all of your checkouts. I will probably need some of your info and help on my
650 before long. I have about 850 miles on it now.

quote:

Originally posted by ATVer:

You Grizz riders leave me alone!

Aww, ATVer,,you know we was just funin ya

Yes I do, and I enjoy it way too much!

quote:

I still don't have that sucker back together, I should have wrote down where the parts came from I guess.

Hey ATVer,,maybe Back2 is making a video of putting his back together,

no vids but i have lots of picturs

Back2,,we need a progress report,,and pics

quote:

Originally posted by back2sportsman:
the sensor is called a "speed sensor" i guess that it tells the ecu how many rpms the gears are turning.

i'm just going over almost everything and doing a compleat one year inspection. I have learned more about the outlander in the last week than in the last year. i have read both the service manual and engine manual cover to cover more than once. (i'm a mechnanical nurd and i have wrenches in my pocket protector)

This is too funny and I wish I had a guy like you around when I blew my clutch last July - it actually wasn't the clutch (the dealer tried to tell me that's what I needed) a great friend of mine and his wife ended up helping me fix it. Who cares if you are a nurd if you can fix wheelers! Good luck getting it all back together ... Hmmm makes me wonder if I should be checking any sensors? Thanks for letting us in on the info!

Backtosprotsman, that speed sensor over time will gather metal shavings and is necessary to remove and clean every 50 hours or so to keep the PCM in tune with that particular sensor. I took mine out at 22 hours just to check it and it was clean. I coated the whole outside of the sensor with dielectric grease to ensure seal and to keep the O-Ring lubed and protected from the elements. Change the oil and O-Ring and grease her up and youy should be good to go.

Hopefully you didn't sustain any damage internally..

Dang that is an old post. Oh well good info for those learning the ropes with this bike