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Old 09-06-2012, 02:23 PM
Billycalexander's Avatar
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1997 Xplorer will not shift

I have a 1997 Xplorer 500 that has been getting hard to shift from forward to reverse or reverse to forward no matter if it was running or not. Now it will not shift at all. I searched but couldn't find this particular problem discussed on any thread. Anyone got any ideas, hopefully there's an adjustment in one of the shift linkages that will fix it???

Thanks in advance
Billy Alexander
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Old 09-07-2012, 06:30 AM
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The problem more than likely will be the shift linkage. It can be adjusted. It has to be set just right. The rod end at the shifter will be left hand thread. Disconnect the rods from the shifter. I think it is hung up in 2 gears low and reverse. The long rod that connects to the rear bell crank is for HI and Reverse. The rod moves forward for reverse and back for HI. The front bell crank is for low gear. It moves forward to engage in LOW gear. Work the rods manualy while rolling the atv back and forth to get it disengaged out of both gears. I hope this will help you.
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Old 09-07-2012, 07:09 AM
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thanks tt425, I'll work on it today and let you know how it turns out!

Billy
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Old 09-07-2012, 09:47 AM
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Ok. No problem
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Old 09-07-2012, 02:29 PM
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the shift lever itself is a poor design and the pin that the rods connect to at the lever wears out in its housing. Also check to make sure that the Bell crank is not cracked.
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12 Starfire Blue Sportsman 850XPHO LE EPS:
- Fender guards, 3500lb PolarisHD winch, Polaris hand warmers, Powermadd hand guards, HID lights, Guru Front Guard, Ricochet A-Arm guards, front L&R box, Uni Air Filter. 27" Black Diamonds, Odyssey Battery, Rhino front axles, QSC clutch kit

12 Bronze Mist Sportsman 850XPHO EPS
- 3500lb PolarisHD winch, Polaris hand warmers, Powermadd Hand guards, HID lights, Guru Front Guard, Ricochet A-Arm guards, Front L&R box, Uni Air Filter. 27" Black Diamonds, Odyssey Battery, Rhino front axles

08 Sportsman 500HO
-26" STI Black Diamond, Kimpex box with seat, Rack/Fender guards, Uni Air Filter, HID lights, Ricochet A-Arm guards, Polaris 3500HD, Polaris hand/thumb warmers, EPI clutch, Rhino front axles

01 500HO Plow Machine
-Kenda Bearclaws, Kimpex Plow, hand warmers, Warn winch

Faithful friends no longer with me:
94 Sportsman 400 4x4- owned 18 years
2000 Xplorer 400 4x4- owned 10 years
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Old 09-10-2012, 09:17 AM
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I took the two shift rods off the shifter box and it made no difference in the ability to shift. I was actually able to shift it some this weekend but not now. Since the problem remained with the rods disconnected, I guess I'll be tearing into the shifter box? Also it has electrical wires coming from it, are they just indicator wires for forward and reverse and neutral, or some type of lockout/safety feature that might be malfunctioning?

Thanks

Billy
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Old 09-10-2012, 09:50 AM
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If it made no difference with the rods disconnected that means you have a problem with the transmission.
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Old 09-10-2012, 05:08 PM
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I disconnected them from the shifter box so with the shifter box disconnected it(the shift knob)still would not move. the rods would work the transmission easily just with me pushing them by hand.
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Old 09-10-2012, 06:13 PM
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you need a new shift lever. You really cant fix what is broken. Once you take it apart you will see why.
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12 Starfire Blue Sportsman 850XPHO LE EPS:
- Fender guards, 3500lb PolarisHD winch, Polaris hand warmers, Powermadd hand guards, HID lights, Guru Front Guard, Ricochet A-Arm guards, front L&R box, Uni Air Filter. 27" Black Diamonds, Odyssey Battery, Rhino front axles, QSC clutch kit

12 Bronze Mist Sportsman 850XPHO EPS
- 3500lb PolarisHD winch, Polaris hand warmers, Powermadd Hand guards, HID lights, Guru Front Guard, Ricochet A-Arm guards, Front L&R box, Uni Air Filter. 27" Black Diamonds, Odyssey Battery, Rhino front axles

08 Sportsman 500HO
-26" STI Black Diamond, Kimpex box with seat, Rack/Fender guards, Uni Air Filter, HID lights, Ricochet A-Arm guards, Polaris 3500HD, Polaris hand/thumb warmers, EPI clutch, Rhino front axles

01 500HO Plow Machine
-Kenda Bearclaws, Kimpex Plow, hand warmers, Warn winch

Faithful friends no longer with me:
94 Sportsman 400 4x4- owned 18 years
2000 Xplorer 400 4x4- owned 10 years
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Old 09-12-2012, 10:10 AM
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Good news

the boot had a hole in it and there was water and muck all in the shifter box with literally no oil. I took it all apart except I couldnt find the stop pin, it works fine now but not sure yet if the electrical indicator switch is shot or not, i put it back on the bike without the electrical loom/switch and it runs/shifts fine so I guess there is no lockout just an indicator function. So is motor oil or gear oil better, it really didn't seem to matter as its not a rapidly moving system.


billy
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