RayBoy

I’m not sure if that damage on the fork happens as a result of the broken roller or caused the broken roller. I am missing a spacer shown below. Number 19 in this pic. It’s a spacer/lock washer so maybe that the problem? I sure appreciate the help here. I’ll assemble things as you suggested but I’m thinking my problem could com from a missing spacer.

I don’t see any links to eBay.

I think I’ve figured it out. I’m missing a spacer. It looks like it came from the factory that way. Number 19 in the picture is not there. So, the roller has constant pressure applied to it when it’s in high or low range, and over time, the roller breaks. Any thoughts?

I replaced the forks after the first time the roller broke. Do you think it would become twisted AFTER it was installed? I’m not sure if the damage happened before or after the roller broke.

The shift forks don’t appear to be blue on the ends. There was noise coming from the motor in high and low range use and I’m not sure if the fork damage came as a result of the broken roller or if it was damaged along with the roller. I suspect if the fork was being damaged for 5 years, it would looks a lot worse. After the first time this happened about 4-5 years ago, I replaced both forks (which I’m doing again). Do you think there’s a problem with the shift drum? I’m kinda baffled

Hey all, I’m having a problem trying to solve why my shift fork roller keeps breaking. I have a 2009 Suzuki King Quad 500 and now, for the second time, one of the shift fork rollers has broken and was causing some transfer issues. Again, this is the second time this has happened. I can’t figure out why this would be a recurring problem. It happened about 4 years ago. Do the forks rattle in the case enough to eventually break? The quad doesn’t get a ton of hard use. Yard work and snow removal in the winter. I thought it may be because I’ve been pushing snow in high range 4x4 but would that break a roller? I would sure appreciate any help. Thanks Ray from SK