Yet, it's strange that the same failure mode (same broken gears and same place in the side cover has broken) has occurred twice - once with the original parts and now again with a second, albeit used, set. Of course, we don't really know if the first break you experienced was on the original parts - the previous owner could have gone through this too...
Anybody seen similar failures in their 660's? Willy, you mention impact wrench damage - have you seen or heard of damage to the side case from this also?
Shelrad: A little more detail on the 'loop' that holds the 'pin' might help us determine where the unusual loads are being generated, but these descriptions don't lead us to what really broke...
You can download the service manual from the top of the 660 maintenance section. Would you please re-describe this issue using parts names from the manual?
'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'02 Honda 400ex, DiamondJ +3 A-arm widener, Lonestar anti-vibe
Last edited by QuadManiac; 04-24-2012 at 12:52 PM.