Newbie with locked rear wheels on Sportsman 500 - Polaris ATV Forum
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post #1 of 4 (permalink) Old 03-20-2017, 10:19 AM Thread Starter
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Newbie with locked rear wheels on Sportsman 500

So I am pretty much brand new to ATVs, but have some mechanical skill. I bought a pretty well used 2005 Sportsman 500 HO last fall and rebuilt the top end of the motor. Used the machine through the winter plowing the driveway and some small jaunts around the neighborhood. Everything seemed to be going well, until just the other day. My son took it on a trail and was headed up a hill in LOW gear with the AWD turned on. Part way up the hill things just locked up and the wheeler would no longer move, found the wheels locked up. The shifter was also locked in LOW. Got the machine home and on jack stands so all 4 wheels are off the ground. Was able to work the shifter loose so it now goes through all the gear positions. Engine starts and runs fine. Looking at the belt from the large breather hole on top of the belt housing, the belt looks OK of what we can see of it. The rear wheels barely rotate forward or reverse before clunking to a stop, and the front wheels spin freely forward, but only barely spin backwards. Brakes are not locked. Best I can surmise by what I've read is I'm in for pulling the tranny and cracking it open. Ideas as to what may have failed?
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post #2 of 4 (permalink) Old 03-20-2017, 03:17 PM
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Polaris warns everyone loud and clear not to engage 4wd while under throttle load. Severe damage to the 4wd system can occur and probably did. The damage may not be limited to the transmission but also the front drive unit. You'll need an FSM to help along the way if doing this yourself. Luck.

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post #3 of 4 (permalink) Old 03-21-2017, 06:04 AM Thread Starter
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Wow, that does not sound good. Although the AWD switch was turned on while sitting still at the bottom of the hill. After watching some videos I wonder if the large chain that goes to the gear at the back of the trans broke and jammed things up inside?
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post #4 of 4 (permalink) Old 03-21-2017, 06:19 AM
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take at first your belt cover off and inspect your belt closely,
then take the belt off and see if you can turn your wheels.
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