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post #1 of 4 (permalink) Old 08-15-2010, 02:06 PM Thread Starter
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please help...pops out of high range@25mph

I have a 1994 300 4x4 and have a problem with it popping out of gear when hitting about 25 mph in H range. Previously I thought that it was a problem with popping out of R so I had a post I started for that. Since then I figured out the proper place for the shift rod to be adjusted to and now it goes into reverse fine and into high fine but at 25 mph it feels like it surges a couple times and then pops out of gear completely. ANY suggestions ?
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post #2 of 4 (permalink) Old 01-02-2011, 06:14 PM
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hope you get this figured out as I have a similiar problem after adjusting my gear linkages it stopped for a little while but now it is popping out of low gear.

2001 Polaris Sportsman 4x4 500 HO [A01CH50AB]
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post #3 of 4 (permalink) Old 01-03-2011, 12:51 AM
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Are you sure you adjusted it correctly? Sounds like it may be out a little bit, but when mine was out of adjustment it was hard to get it into high but when it went in it would stay in. Check the bolts holding the trans to see if they maybe worked loose and the drive belt is pulling the trans forward under power.

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post #4 of 4 (permalink) Old 01-06-2011, 04:23 PM Thread Starter
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Fixed it

Found that there are these collars inside of the trans that the shift forks move and the collars have sprag teeth which engage in the gear sets to engage into H,L, or R. The sprags are square cut and if they wear they essentially become a ramp that given the right amount of load will instead of holding into the selected gear like a square cut will push the collar away from the gear set causing the bike to pop out of gear. Adjusting the shift rod one way will fix the popping out of reverse and adjusting the other way will stop popping out of high but since the sprags are worn down, it won't be able to work int both. The low range sprag is the same except adjustment may help a little more until heavy load is put on it, then it pops out. The root cause of this would be I imagine it would be the grinding sound that the bikes make when the rpm is too high and it is being put in gear combined with shift fork wear. I replaced the guts in my trans and it works perfect.
Bolt, for your bike go to the bike bandit web site, the part is #28 in the transmission internal illustration "dog, engagement, low" I would also suggest replace #19 "shift fork, low, sub-asm" if the ends of it look bent and/or worn or the detent groove looks worn on the shaft. The tips of the fork should have nubs and the detent groove on the shaft should be nice sharp cut v shape.

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Last edited by speedhammer; 01-06-2011 at 04:35 PM.
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