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  1. #1
    skiversinc's Avatar
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    Question How to repair a stiff/jammed Reverse lever on Virage, MSX, Genesis with reverse lever

    Can anyone tell me how to remove the reverse selector from my 2001 Virage TX 1200?

    Basically the cam shaft has sheared & I'll be needing a new one (see WTB in classifieds) I just need to know how to get it out!!

    Any help you can offer will be gratefully recieved.
    Last edited by K447; 07-03-2011 at 07:26 PM.


  2. #2
    i would download the sevice manual for this model. u can go to www.polarispartshouse.com and selecting polaris parts lookup and follow the steps. see if that helps u atall with getting it off

  3. #3
    skiversinc's Avatar
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    No info

    Thanks for the suggestion. The manual isn't really much help I'm afraid. All it says is that it shouldn't need much maintenence! That's it! Not very helpful at all.
    I thought possibly there might be someone on the forum who might be able to shed a bit more light on the matter, from personal experience.
    Thanks for the suggestion though.
    Cheers

  4. #4
    ya i was looking at the pictures of ur pwc and ur reverse seems much more complex than my slt 700 but what is it exactly u are trying to take off... can u shw me on this pic if it is the right model?(i could not find any with "1200" in the name)

  5. #5
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by skiversinc View Post
    Thanks for the suggestion. The manual isn't really much help I'm afraid. All it says is that it shouldn't need much maintenance! That's it! Not very helpful at all.
    I thought possibly there might be someone on the forum who might be able to shed a bit more light on the matter, from personal experience...
    Download the 2001 Virage TX PARTS manual.

    It has an exploded diagram of the reverse assembly on page 17.

    Or use the Polaris Industries online parts diagram for 2001 Virage TX

    I have never removed a Virage reverse assembly (Edit: I have now), but it is a hard spot to get into under the steering shroud, beside the oil tank.

    You can take the Virage oil tank out, if you need more elbow room.
    Unscrew and move aside the reverse electrical switch bracket, and disconnect and cap the oil filter from the nipple on the rear end of the oil tank.
    Disconnect the oil level sender wire connector.
    Now you should be able to lift and wiggle the oil tank forward. Be careful not to damage the nipple on the rear, or the little vent fitting on top.

    The oil tank has a recess that fits around a bump on the fuel tank, so you must lift and twist the oil tank to clear that bump. Once you get it forward the first inch or two, it comes right out. The oil tank is actually rather long.
    Last edited by K447; 06-04-2012 at 11:45 PM. Reason: Fixed broken web link

  6. #6
    skiversinc's Avatar
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    Thanks for your input guys.
    Basically, the part I need to replace is number 12 in the diagram. Unfortunately, I think I need to remove the whole unit in order to access this part.
    It is a bit cramped under there, but I think I should be able to get into the unit - if I know how to get it out.
    Are the reverse units bolted into place?
    There's a ring under the shroud which is screwed into place with 4 philips screws. The shaft fits through the hull, through this ring, and the selector fits onto the shaft from there.
    It's the other end of the shaft which seems to be screwed to item number 9. However, this is screwed together from the other side, so it's unaccessible. There IS a metal bar which bolts onto the hull and onto the centre of the reverse mechanism (item #26).
    I think I need to remove the entire unit due to its construction, but I can't seem to work out how to do this properly.
    Any ideas?

  7. #7
    Click avatar for tech links/info, donation request K447's Avatar
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    You could try sending Private Messages (click on the poster's name at the left of their post) to the members on here who have recently parted out a Polaris with this type of reverse handle (Virage and Genesis models without electric reverse). Look in the Classifieds to see who has parted one out.

    They might be able to tell you how it comes out, or perhaps take some photos of it out of the hull, or even sell you the whole handle + mechanism if they still have it.

  8. #8
    Click avatar for tech links/info, donation request K447's Avatar
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    Arrow How to repair a stiff/jammed Reverse lever on Virage, MSX, Genesis with reverse lever

    Well, my own Virage TXi reverse level was binding and getting hard to operate, so I had a look at how it works.

    Per the attached photos, you do not need to remove the entire mechanism from the hull to fix it.

    Pry the plastic cap (1) from the outside of the reverse handle (33). Use a 10mm driver to unscrew the long bolt (2) inside the hollow handle. Remove the handle.

    Under the hood, remove the cotter pin (25) and washer (18 ) connecting the reverse arm (26) to the reverse cable (34). Slide the cable out of the hole on the reverse arm.
    Note: This step is not entirely necessary, but it is how I got mine apart.

    Remove the Philips head screw (19) holding the Reverse Lock (17).

    Remove the 10mm bolt (15) holding the metal bracket to the center of the large reverse arm. Don't lose the washer underneath (14).

    Note: There is a captive nut on the back side (13).
    Don't push too hard on the bolt while unscrewing it, or the nut will push out into the hull and go hide somewhere.

    Gently bend the metal bracket (20) away from the reverse arm, enough to allow the reverse lock (17) to be removed.

    Alternate method; If you don't want to bend the metal arm, remove the hidden 10mm nut from the rear support stud (30). This will allow the metal bracket to be removed. Don't drop the nut or washer

    Slide the plastic reverse lock pawl (17) and spring out from under the metal bracket (20). Don't lose the spring (16) that is inside.

    Now you can use the 10mm driver to gently tap on the end of the cam shaft (12). Mine was quite snug. Tap the cam shaft all the way through. The pinion (9) will come with it.

    In my case, the problem was that the nylon plastic cam shaft diameter seems to have expanded (or the pinion gear hole shrank), enough that the pinion no longer freely rotates on the cam shaft.

    This causes the reverse gear arm to remain locked when you try to move the lever, and it feels like it has jammed. Fight with it enough, and the lock suddenly releases and works, or you break things

    I had to use a hammer and drift to tap the pinion off the cam shaft, and it was tight all the way. Time to do some fine sanding...

    Apply sandpaper to the shaft until the pinion slides smoothly on and off the shaft. Also make sure the shaft now slides freely into the hole where it goes when re-assembled.

    The pinion (9) needs to freely rotate on the cam shaft (12) (next two photos).

    Apply waterproof grease to all contacting and sliding parts, shafts and gear teeth as you reassemble.

    I see that Babbitts shows the cam shaft part# 5433955 being SUBSTITUTED BY 2202170 ($18US), also the pinion part# 5434067 also SUBSTITUTED BY 2202170
    Sounds like an updated version, perhaps because of the binding shaft issue

    This video shows the pinion and cam action, without the locking pawl present.
    Note the motion of the cam before the pins move the pinon gear.




    And finally, mounted in the hull.
    All moving parts have been greased.

    It really is about a two finger amount of force to move the reverse lever when everything is working properly.


    Update: In addition to reducing the binding friction on the pinion shaft, the slotted holes can be elongated, allowing the latch to be lifted farther away from the pawl slot.

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    Last edited by K447; 11-02-2016 at 05:54 PM. Reason: Added more detail, pictures, and video


  9. #9
    skiversinc's Avatar
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    Talking Thank you

    Guys, you have been so much help! Especially you K447! Don't tell me you actually went out & took yours off so you could give me that information???!!!

    You're a legend. Your guide has enabled me to get my cam shaft out & a new one has been ordered.

    Thanks again.

  10. #10
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by skiversinc View Post
    ...Don't tell me you actually went out & took yours off so you could give me that information?...
    ...Your guide has enabled me to get my cam shaft out & a new one has been ordered...
    Well, I was already working on my Virage, to fix the burned out coupler.

    Once that was done, I figured I might as well fix my own sticking reverse lever. Since you needed the info anyways, it seemed like a good time to get into it.

    Did you order the updated part# 2202170, which appears to include both cam shaft and pinion?

    Photos show the mounting area for the reverse mechanism.

    To remove the four flat head screws that are tucked just inside the cowl hole, I needed to remove and loosen the front shroud bolts. Don't loose the spacer washer tucked between the two plastic layers

    Then I could lift and flex the shroud enough to get a screw driver on the screws, and work them out.
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    Last edited by K447; 04-10-2010 at 10:00 PM.

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