How to repair a stiff/jammed Reverse lever on Virage, MSX, Genesis with reverse lever

[skiversinc]

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.

[bossd]

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)

[K447]

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 from the same web page (left column, bottom item).

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

I have never removed a Virage reverse assembly, 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.

[K447]

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.
YouTube - Polaris Virage/Genesis/MSX reverse handle mechanism motion 2

Here you can see the reverse sensing switch and Forward/Neutral/Reverse detent pin
YouTube - Polaris Virage/Genesis/MSX reverse handle mechanism motion 2

When it is working properly, the reverse mechanism looks like this.
Note how the cam motion releases the locking pawl before the four pins start moving the actual gear. This is how the system allows the operator to move the reverse bucket usign the handle, but jet pump force cannot move the bucket if the locking pawl is in position.
YouTube - Polaris Virage/Genesis/MSX reverse handle mechanism motion 3

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.
YouTube - Polaris Virage/Genesis/MSX reverse handle mechanism motion 4

[skiversinc]

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.

[K447]

...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.

[skiversinc]

Re: cam shaft kit

Thanks so much for doing that. I really do appreciate it.
Apparently, according to my dealer, the cam shaft comes as a kit now, so I'm thinking that's the new part number.

Once I had your guide in my sweaty little hands, the whole thing was out in about 10 minutes. Thanks again.
Maybe we could get that guide pinned somewhere in case anyone else has a similar problem.

[K447]

MSX reverse lever handle retaining bolt is on the inside

Update: The MSX reverse lever is the same mechanism inside as the Genesis and Virage, but the handle is different.



On the MSX, there is a long bolt running through the cam shaft (item 28 ) that you undo from the inside the hull to remove the handle. It is a 10mm head. Loosen the bolt until the handle becomes free, then pull/wiggle the handle straight off the shaft.

Once you get the long bolt out from the inside, the rest of the repair is the same as the Virage/Genesis method outlined earlier.

[beerdart]

Great info.

[mjb5046]

New member here and an owner of two 03 MSX 140's. Some way, some how, I lost that spring (16). Can I pick this up at a local hardware store. I have purchased a spare spring but the other one is missing also so I am short one. Also, after looking over the machines I noticed that the paddle wheel, on one of the machines, is missing. Any advice on where I could find one. By the way I love this site and the info.

Thanks,


Matt

[K447]

New member here and an owner of two 2003 MSX 140's.

Some way, some how, I lost that spring (16). Can I pick this up at a local hardware store?

I have purchased a spare spring but the other one is missing also so I am short one.

Also, after looking over the machines I noticed that the paddle wheel, on one of the machines, is missing. Any advice on where I could find one?

By the way I love this site and the info.

Thanks,

Matt

Welcome to the Hulk Matt

Parts sources can be found through my signature links below.

Polaris part # 7041995 SPRING-COMPRESSION is about $10
I am sure you can find something similar locally, but make sure it will not rust. I might have a spare spring around here somewhere

Those springs do tend to fly out and go hide if you are not careful when taking the reverse mechanism apart. It might be somewhere in the bottom of your hull. Look/feel under the engine and among all those hoses. Also look around the rear where the jet pump tunnel is. Lots of hiding places for a little spring

The 2410344 ASM-PADDLE,WHEEL speedometer sensor may not be available new. Call a few of the listed suppliers.

[beerdart]

The paddle wheel from a Yamaha or Seadoo will fit. Do you need the whole assembly or just the wheel?

[mjb5046]

Thanks guys. I'll check with my local hardware store for the spring. Now that I think about it I'm not sure that I didn't lose the washer that holds the metal bracket. I'm sure that would be a standard stainless washer correct? I sure hope these machines work! Got them from a guy I know and he needed the $.

Beerdart, I just need the paddle wheel and pin.

[K447]

The paddle wheel from a Yamaha or Seadoo will fit. Do you need the whole assembly or just the wheel?

Yamaha or Sea-Doo part numbers for the paddle wheel?

Actually, do you know if the whole Polaris speed sensor assembly will interchange with a Yamaha or Sea-Doo part, other than the connector/cable into the hull?

---------- Post added at 01:43 PM ---------- Previous post was at 01:41 PM ----------

... I sure hope these machines work! Got them from a guy I know and he needed the $ ...

Do check the basics before you go riding.

Compression, fuel pressure, correct spark plugs, etc. Also check for loose hose clamps, nuts, bolts, and so on. Check everything you can.

Click my signature links and prepare for some reading

[mjb5046]

I will try and check as much as I can. Thanks K447. I use to live in Mississauga when I was younger. Looks like one of my msx's is the same as the one in your picture.