btilus

Yeah, the waterpump is stock. I gave it the once over and everything looked good, but I hadn't thought of a radiator clog. I'll give that a look. I also considered that the oil could be metal shavings. Is it worth looking at the clutch? Yeah, that's a good idea on the trans bearings, I'll do that! Thanks!

Ok guys I've got a bit of an odd one here. First off..I'm a cross country Banshee rider. Lots of wide open driving on the plains, roads, and hills (yes there are some) of South Dakota. In the summer of 2009, I was ridding my machine at approximately 30mph when the tires locked. Couldn't get the machine into neutral (which of course made it fun getting back to the truck). Anyways, over the winter I finally had the time to get into it. After removing the engine and splitting the case I discovered what I had expected, a broken gear fork and 3-4 gears stripped of some teeth. So I got on ebay and got a used trans and swapped out the parts as needed. Put the whole thing back together and had it ready for this summer. So this year I took it out again, and it did not go as I had expected. The first 10 hours or so were pretty good, couple of times had trouble kicking it over, but nothing out of the norm for a 10 year old machine. Then near the end of the second day it started getting temperamental. We had just started out again after lunch when after about 1 hour I noticed that I had coolant boiling out of the case overflow. So I gave it a 10 min break to cool down before continuing on the trail. About 30 min after that I was climbing up the gully of a large hill when I noticed it boiling over again and gave it another quick break. When I went to start the machine again I noticed that the clutch really wasn't engaging much, so once I got it started I used the throttle and the break to make my way up the rest of the hill. Once I got to the top of the hill I gave the machine a 30min rest before continuing on. After about another 30 min of driving we were on our way back to the truck when at approximately 20mph the wheels locked again. I just got the case split again and found a bunch of issues. First, both pistons had damage, but rods and cylinders look fine. Again I had missing teeth in the transmission gears and this time the gear selector was also missing a chunk about the size of a quarter. The other thing was that the oil in the case was a very silver color. So here's my questions. Why do I keep having transmission problems? Why did the engine keep boiling over? What's up with the silver oil? I plan on replacing the transmission, gear selector drum, and pistons. Is there anything else i should add to this list? Sorry, I know it's a lot of questions, but I've already had this machine completely broke down twice now and I really don't want to have to do it again. Thanks!