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post #1 of 6 (permalink) Old 04-09-2019, 01:25 PM Thread Starter
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Question Sportsman 500 Gear Selector

I got this 1999 Sportsman 500 4x4 and I was out one day and went to shift into low to load it on my trailer. So it wouldnt go into Hi or Lo, only reverse. So when I got home I tore the gear selector unit apart and it was disgusting, total rust. So fast fwd to today. I finished rebuilding the selector unit and put it back on, felt good. Go to the farm and worked fine for a while. Then the same thing happened, stuck in reverse and cant get into Hi or Lo. Took a pair of pliers and moved the Hi lever on the tranny manually and got it to go. So obviously it wasnt the rusted out gear selector box, any one have this happen? I am going to try and adjust linkage and see what happens. I just dread if it is something in the trans.
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post #2 of 6 (permalink) Old 04-10-2019, 06:50 AM
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Disconnect the linkage and try shifting by turning the bellcrank with pliers, crescent wrench or whatever - it it will shift and stay in gear, it's not the transmission

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post #3 of 6 (permalink) Old 04-10-2019, 11:31 AM Thread Starter
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I cleaned up the linkages and adjusted and seems to be fine so far. Keep fingers crossed.
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post #4 of 6 (permalink) Old 04-10-2019, 01:42 PM
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The bell crank on those will start to chew up the splines if the nut ever gets loose. That can cause your problem. The bell crank will move but won't always move the shaft all the way.
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post #5 of 6 (permalink) Old 04-10-2019, 02:48 PM
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Quote:
Originally Posted by Quintin View Post
The bell crank on those will start to chew up the splines if the nut ever gets loose. That can cause your problem. The bell crank will move but won't always move the shaft all the way.
It should chew up the crank lever before the shaft splines. Its aluminum and the shaft is steel. I've had to replace a few bell crank levers but never the shift shaft itself. The shaft splines will get full of aluminum and need to be wire brushed good to remove it before installing the new lever though.
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post #6 of 6 (permalink) Old 04-11-2019, 06:16 AM
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That was what I meant. The lever is aluminum and will loose it's splines and never hurt the shaft.
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