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What are the odds of me breaking them. I haven't but I have heard about it? I think the straight cut gears went in the 09's not the 08's. I run 27" ITP XTR mud lights. I just got my mind turning. As I understand it all prowlers up to 09 and all h1 cats up till 09 had the weaker gears. How big of a problem is this? Here is a pic of my cat.
 

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I would say that the odds are pretty good you can break them if the side cover breaks or flexes. If the side cover does not flex like if you had a heavy duty side cover made you probably wont break em. They break when the load on the ring gear load button is to much and the side cover flexes. Here is a few photos of a heavy duty billet one I had made.



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I was talking about the main drive gears in the engine. I know hey changed them to straight cut in 09. I just would hate to have to tear the hole engine down because of this.
 

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I have heard of them being a problem but I have a 650 xt with hl lift and lift springs with the clutch kit and cdi performance box and I am running 32 in silverbacks I have run mine as hard as it will and the only problem I have had is front and rear differentials and I have broke the input shaft three times so I would not worry about it unless it breaks then fix it
 

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The gears

We just torn our motor down and got the gears out of the transmission, someone told us to put the new bevel gears back in it ( like whats in the 09) but the parts list has the same part#.. Does anyone have a anwser?:)
 

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The helical gears (secondary drive and driven) grenaded on my '08 650XT at around 3,000 miles. Not running anything different but replaced the warn out Goodyear OEM tires with ITP BajaCross, same sizes as original.

AC was really backordered on the replacement gears, so I believe there is a problem. The replacements ended up being square cut; the technical rep at AC said that the helical gears had problems so they went back to the original gears. He said these would not break.

My helical gears looked like the induction hardening on the face started to come apart.

The new gears whine like crazy, and tend to torque lock a bit (have to throttle a little to shift from Lo to Hi or Reverse to Hi).

That's what I know.
 

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I like the Bilstein ride a lot. The only thing I wish is that the machine would have more clearance (with preload set according to spec, I have about 10.5" as opposed to the 12" I had with stock shocks). These Bilsteins are big and strong, so I seriously doubt I will ever break one (unlike the OEM junk). Also, Gary Fries at MicroTouch (maker of Bilsteins) is very helpful, and knows a lot about suspension.

I would be interested to see what kind of ground clearance others are getting with Kings, etc.
 

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The old beval gears are a promblem for the guys down south that are running big heavy mud tires and what usally takes them out is when you drive in reverse with a load on them, they had them because they wern't as loud, I think you will be ok if your foot isn't to heavy.
 
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