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03-04-2011, 07:40 AM
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Junior Member
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Member #12611
Join Date: Mar 2011
Posts: 3
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04 Sportsman 500 shifting hard
I have a 04 that I use for plowing and it started to get real hard to shift out of low. This happens most all of the time when plowing now. I have made sure the idle is below 1000rpm but it still shifts hard. I usually have to shut off the engine to get it to shift out of low. Does anyone know of this problem and what I can do to fix it please?
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03-04-2011, 08:22 AM
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Super Moderator
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Member #193
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Location: Port Angeles WA
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Welcome to the board! 
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03-04-2011, 01:51 PM
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Extreme ATV Enthusiast
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Member #2821
Join Date: Jan 2010
Location: North Pole, AK.
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I would start by replacing your belt. While you have the cover off clean the clutches and make sure you don't have any grooves worn in the sheaves/ramps. Make sure that your motor mounts are tight and that the transmission is tight so that the clutches are lining up properly. If it came on gradually I would bet it is the belt. My 700 did the same thing. I noticed when plowing that when I went to put it in reverse out of low it came out of low hard. It gradually got worse. It always shifted smoothly with the engine shut off. Some times if I popped it into neutral before I came to a complete stop it would slip out easily but if I waited until stopped then I felt like I was breaking something trying to get it out of gear. The new belt cured this. My old belt looked good. No chunks or serious wear but it was 3 going on 4 years old.
__________________
04 Sportsman 700 efi black and silver, Big Gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Polaris heavy duty front springs and gas shocks, Black Rock wheels,Polaris(warn) winch and plow, 2 inch receiver, Filtermag.
08 Sportsman 500 efi Browning camo, Big gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Polaris(warn) winch, Cycle Country plow, 2 inch receiver, Black rock wheels,Filtermag
00 Magnum 325 not very HO green, rolled wrecked and rebuilt,heated grips and thumb warmer, Filtermag.
88 Yamaha Warrior 350 my first
88 Honda Foreman 350 takes care of the yard work
91 Suzuki DR 350 solves the urge to ride wheelies and catch big air
05 Kawasaki KLR 650 scratches the paved road itch
92&93 Indy 500 EFI SKSs takes care of the need to get away from home in the winter
04 Yerf Dog spiderbox buggy was supposed to be for the kids but I find I cant quit tinkering with it
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03-04-2011, 02:06 PM
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Junior Member
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Member #12611
Join Date: Mar 2011
Posts: 3
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04 Sportsman 500 shifting hard
Thank you for the advice, that makes perfect sense. And this is the original belt -6 years old so is likely to be soft and chewed up. Thanks again.
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03-04-2011, 03:28 PM
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Extreme ATV Enthusiast
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Member #2821
Join Date: Jan 2010
Location: North Pole, AK.
Posts: 424
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Let us know if it works. I for one was sceptical when I recieved the advice I passed along to you. My belt looked good. It wasnt.
__________________
04 Sportsman 700 efi black and silver, Big Gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Polaris heavy duty front springs and gas shocks, Black Rock wheels,Polaris(warn) winch and plow, 2 inch receiver, Filtermag.
08 Sportsman 500 efi Browning camo, Big gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Polaris(warn) winch, Cycle Country plow, 2 inch receiver, Black rock wheels,Filtermag
00 Magnum 325 not very HO green, rolled wrecked and rebuilt,heated grips and thumb warmer, Filtermag.
88 Yamaha Warrior 350 my first
88 Honda Foreman 350 takes care of the yard work
91 Suzuki DR 350 solves the urge to ride wheelies and catch big air
05 Kawasaki KLR 650 scratches the paved road itch
92&93 Indy 500 EFI SKSs takes care of the need to get away from home in the winter
04 Yerf Dog spiderbox buggy was supposed to be for the kids but I find I cant quit tinkering with it
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03-06-2011, 05:08 PM
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Extreme ATV Enthusiast
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Member #3805
Join Date: Mar 2010
Location: us
Posts: 436
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I would also suggest to inspect you drive belt for a start.
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03-09-2011, 06:31 AM
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Junior Member
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Member #12611
Join Date: Mar 2011
Posts: 3
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Thank you for the feedback bakada and elmerkit. I replaced the belt and it is shifiting much better. The belt looked supprisingly good for 6 years old but it was thinner and cracked.
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03-09-2011, 08:16 AM
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Extreme ATV Enthusiast
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Member #2821
Join Date: Jan 2010
Location: North Pole, AK.
Posts: 424
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Good deal that sure beats the alternative of new clutches or trying to get your old clutches aligned.
__________________
04 Sportsman 700 efi black and silver, Big Gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Polaris heavy duty front springs and gas shocks, Black Rock wheels,Polaris(warn) winch and plow, 2 inch receiver, Filtermag.
08 Sportsman 500 efi Browning camo, Big gun Evo exhaust and tuner,3 light mod,reverse override,bar and thumb warmers,Moose pregressors,Polaris(warn) winch, Cycle Country plow, 2 inch receiver, Black rock wheels,Filtermag
00 Magnum 325 not very HO green, rolled wrecked and rebuilt,heated grips and thumb warmer, Filtermag.
88 Yamaha Warrior 350 my first
88 Honda Foreman 350 takes care of the yard work
91 Suzuki DR 350 solves the urge to ride wheelies and catch big air
05 Kawasaki KLR 650 scratches the paved road itch
92&93 Indy 500 EFI SKSs takes care of the need to get away from home in the winter
04 Yerf Dog spiderbox buggy was supposed to be for the kids but I find I cant quit tinkering with it
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03-10-2011, 08:39 AM
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Junior Member
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Member #12820
Join Date: Mar 2011
Location: Harrisburg, Pennsylvania
Posts: 7
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My 2006 sportsman 600 was doing the same, it would shift fine when the machine was turned off but not when running. I took the clutch cover off and removed the belt. The clutches seemed to be clean but I blew them out with some compressed air and there was lots of dust also used some brake cleaner to clean everything up. After putting it back together it shifts like new again. I guess just that little bit of dust and dirt effects the clutches and doesnt fully disengage so you can shift.
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