99 500 4x4 grinds bad when shifting - Polaris ATV Forum
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post #1 of 6 (permalink) Old 06-11-2011, 07:17 PM Thread Starter
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99 500 4x4 grinds bad when shifting

hello all first timer here..

just traded a 99 sportsman 5004x4 for some jetski work..

machine in ok shape rarely riden but needs all bushings for front and rear suspension

also here is the main problem it grinds like hell when putting it into any gear
you have to turn off machine shift into gear and sometime rock it then re-start it and go..

and it also sounds like it might be idled up to high could that cause the grinding gear change and a possible bent shift linkage??

and need rear pads and rotor and front pads and caliper along with bushings where to get parts.. thanks
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post #2 of 6 (permalink) Old 06-12-2011, 05:25 AM
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What are the rpms set at.....?
Check the belt...................?
That is the best place to start and then we will need more info
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post #3 of 6 (permalink) Old 06-12-2011, 05:41 AM
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Welcome to the board!

I tried setting my password to "penis" but it said my password wasn't long enough...
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post #4 of 6 (permalink) Old 06-12-2011, 06:16 AM
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Hi, pull the clutch cover off, see if the primary clutch is engaging at idle. I suspect your primary needs a rebuilt.
Good luck
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post #5 of 6 (permalink) Old 06-12-2011, 10:32 AM
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Quote:
Originally Posted by nick34 View Post
and it also sounds like it might be idled up to high could that cause the grinding gear change and a possible bent shift linkage??
If it is idling to fast I would look there first. It should idle about 1200 RPM. The fast idle causes the primary to engage the belt spinning the secondary clutch and the transmission causing it to grind going into gear. Pull the clutch cover and If the clutch is grabbing the belt at idle and spinning the secondary try idling down until it stops engaging the belt. If you cant get it to stop engaging the belt by idling down then you need to check the clutch sheaves for grooves or marks. Make sure your belt is good. If you don't know how old the belt is I would change it with a Polaris belt. Make sure motor mounts are tight and unbroken. If none of this stops it from grabbing the belt at idle you might need to align the clutches by adding or flipping washers behind the secondary clutch.

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post #6 of 6 (permalink) Old 06-15-2011, 05:50 PM Thread Starter
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ok guys thanks for all the tips..

i havent pulled the cover off yet im so busy working on jetskis..

i have lowered the idle a tad and it helped alittle but i did notice that the rod end on the long linkage is worn out and so is the piece it screws into its wollered out because if i push the shifter foward into high and reach back and push the rod end and lever back just a bit it goes right in with just a hint of a grind and same with reverse i pull the shifter back and pull the lever and linkage foward and it slips right in ..

only problem is i cant seem to find the worn out part in any micro-fisch..
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