04 SP 600 Shifting issue - Polaris ATV Forum
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post #1 of 30 (permalink) Old 09-12-2019, 06:16 AM Thread Starter
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04 SP 600 Shifting issue

newbie question here
I bought a 2004 sportsman 600 last year and it has been giving me trouble shifting starting this summer. Intermittently it does not want to shift. It is like the shift lever is stuck completely and other times it is shifting like nothing is wrong.
I was talking to a co-worker and he suggested a clutch kit because he thought my clutch was going bad. After installing an EPI kit a month or so ago it still is doing the same thing. One thing I do not like with the kit is that my rpm is much higher when it engages gear than before, like over 2400 rpm. It still idles as before just over 1000 RPM.
Can anyone give me any recommendations?
Thank you
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post #2 of 30 (permalink) Old 09-12-2019, 09:03 AM
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Yeah don't listen to that co-worker for advice anymore. Let's throw a performance item at a system that is improperly working .

So when it doesn't want to shift are the idle RPM's higher then normal???

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
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post #3 of 30 (permalink) Old 09-12-2019, 09:23 AM Thread Starter
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thanks... I wont
I can not say for sure that the rpms are higher than normal. I am really tempted to put the clutch back to factory since I kept the original parts
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post #4 of 30 (permalink) Old 09-12-2019, 09:40 AM
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When is the last time the gearcase oil was changed and what kind of lube was put in it?

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post #5 of 30 (permalink) Old 09-12-2019, 09:45 AM Thread Starter
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It was changed less than 18 months ago (spring of 2018) with Polaris lube from dealer
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post #6 of 30 (permalink) Old 09-12-2019, 10:36 AM
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OK - well then perhaps it can't be attributed to the lube - it's probably something to do with the linkage or something internal to the gearbox

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post #7 of 30 (permalink) Old 09-12-2019, 10:56 AM
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Well you'll have to identify if the shifting issue is happening during a high idle situation or not. So next time it doesn't want to shift chk your RPM's. If its not that we'll move I to the clutch itself.

And yes 2400rpm is a bit high for engagement. The only scenario I see that remotely acceptable is if you have a fully built mud machine. Shouldn't be higher then 2000rpm for belt engagement.

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
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post #8 of 30 (permalink) Old 09-12-2019, 12:18 PM Thread Starter
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I will try to take a look at it again tonight.
I was reading thru this also and I am thinking at looking at this also
https://www.polarisatvforums.com/for...an-2004-a.html
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post #9 of 30 (permalink) Old 09-12-2019, 12:51 PM
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Yes - your gear case is the same as the 700 and you might have a similar problem - pressure washes are wonderful for getting dirt off and getting water into where it should not be.

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post #10 of 30 (permalink) Old 09-12-2019, 02:45 PM Thread Starter
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Well I just opened that area up and it is bone dry. Should I grease it up? if so what kind of grease? Just an all purpose grease?
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