High Gear Grind - 04 Sportsman 600 - Polaris ATV Forum
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post #1 of 28 (permalink) Old 05-13-2019, 10:14 AM Thread Starter
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High Gear Grind - 04 Sportsman 600

My new to me 04 Sportsman 600 has the dreaded high gear grind. It won't even go in for me. When I try to slide it into high at a complete stop it just grinds until I put it back in low etc. I've tried being patient and finesse it etc, but no Bueno. I'll pull off the outer cover and check it out first, but it just seems more like it'll be the gear.
I watched a youtube vid that showed a guy swapping out the high gear which is I'm sure what I'll have to do. The problem is that he doesn't know the part number. I have the service manual, but the trans exploded view is terrible.
Can someone tell me what the part number is for the high gear and how many teeth it has? Not that it should matter, but it's an early 2004 machine. The only difference in the tranny is where the fill and drain plugs are located.

Thanks.
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post #2 of 28 (permalink) Old 05-13-2019, 10:23 AM
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Turn the machine off and see if it'll go in gear. That will tell you if its clutches or something to do with the tranny or linkage.
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post #3 of 28 (permalink) Old 05-13-2019, 10:32 AM Thread Starter
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Turn the machine off and see if it'll go in gear. That will tell you if its clutches or something to do with the tranny or linkage.
Great. Will do. So if I'm able to slide it into high gear with it off, I should be able to start it and have it stay in high gear if I'm lucky?
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post #4 of 28 (permalink) Old 05-13-2019, 10:53 AM
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Yeah, that's the idea. Never try to force one in gear. If it don't want to shift cut the machine off, put it in gear and start back up.
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post #5 of 28 (permalink) Old 05-13-2019, 10:57 AM Thread Starter
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I was able to put it in high gear with the motor off. At first it ground when I started it, but I shut it off, pulled it out of gear, put it back in and started it again. I was able to zip around with it in high.
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post #6 of 28 (permalink) Old 05-13-2019, 10:57 AM
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Oh course, if the one-way bearing is bad in the drive clutch it may not want to start in gear or will try to pull/creep if it does start so hold the brake.
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post #7 of 28 (permalink) Old 05-13-2019, 11:05 AM Thread Starter
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Oh course, if the one-way bearing is bad in the drive clutch it may not want to start in gear or will try to pull/creep if it does start so hold the brake.
No problem there. Also wasn't jamming it into gear. Been around a while, so usually I'm pretty good with machines. Quads are new to me though.
So with all this said, what are you thinking? Gear?
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post #8 of 28 (permalink) Old 05-13-2019, 02:27 PM
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Oh course, if the one-way bearing is bad in the drive clutch it may not want to start in gear or will try to pull/creep if it does start so hold the brake.
No problem there. Also wasn't jamming it into gear. Been around a while, so usually I'm pretty good with machines. Quads are new to me though.
So with all this said, what are you thinking? Gear?
No, if it goes into gear not running and then tries to pull when you crank it you have a one-way bearing bad in the primary.
You can confirm by pulling the clutch cover and belt off and check the one-way in the primary by hand. It should turn easily one way but not the other.
Eliminate the easy stuff first before you think about going into the tranny.
If you find nothing wrong with clutches, drain the tranny oil into a clean pan to check it for metal and go from there.
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post #9 of 28 (permalink) Old 05-13-2019, 03:00 PM
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Sorry, I didn't see your other post about having tried it shut off. If it sorta went in at first but then you got it, you could just have linkage out of adjustment or the bell crank (70) slipped or issues in the shifting mechanism on the side of the tranny under the cover (3)…. #'s 4-8 and 63-65.
That tranny has a park lockout (59) that can cause issues too if not right.
Make sure the clutches are good and then I'd check linkage adjustment and inspect the oil.
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post #10 of 28 (permalink) Old 05-13-2019, 03:25 PM
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Hey Hawk, it just occurred to me... are you saying it ONLY grinds when going into high? Shifts good into other gears?
If so, that may be nothing more than linkage adjustment.
I've been preoccupied with other stuff today and hadn't thought about you saying just high gear being the problem.
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