I have a 04 sportsman 600 and sometimes when I shift it into high it grinds and doesn't engage. Other times it shifts in fine no problem. It shifts into all the other gears perfect. Just sometimes going into high it gives me a problem.
Could one or more of many things....RPM? belt not stopping? old belt? clutch dirty? shift assy worn out, how much slop in linkage? does the shift lever move a lot when in gear or does it feel loose? how many miles/hours on it? detent stop not working? need some more info, you need to eliminate a few issues, some listed here.
If the Rpms where to high wouldn't in grind engaging into each gear?? The belts about 8 months old. The clutch could be dirty haven't looked at it. There isn't a lot of play when it's in gear. Not a lot shifting into the gears either. The machine has just over 1000 miles. Also do you have to have your foot on the rear brake when putting it in drive? Thanks Jon.
You should have to put you rear brake on to shift. Sounds like the bell crank bushing or the shift gears behind it may be worn? Do you do a lot of shifting ie: reverse forward etc.? this would wear the shift gears. If it is the gears easy fix and not too expensive 30-40$ if you do it yourself.
Follow the shift linkage down toward the rear of the foot well you can see bell crank on the end of the shift rod that came from the front, the bell crank attaches to the rod ,goes through a bushing and attaches to the shift gears, there should be an electrical connection there as well which is your gear position sensor. The gears that wear are behind this small plate I think it has 6 small bolts to hold it on, also on the side is your detent hold pin it has a spring that runs to your foot brake. I think if you're having a bit of trouble knowing if you have a H-shift pattern or an inline this may be a problem for you.
The linkage was very loose in the shifter. Just tightened it up. Feels a lot better. I also noticed it is idling between 1400-1500 rpms. I know that's to high. Shouldn't it be around 900-1000 rpms?? I tried adjusting the idle but can see the left side of the carb without removing some plastic. guessing the idle screw is on the left side of the carb? The right side of the carb is very accessible. Thanks for your help!
?? Transmission oil change? it may help? Is the detent pin releasing when you step on the rear brake? The detent spring attached to the brake should move it about 3/8"-1/2" to dis-engage it. you could remove the detent assy to check if that helps shift if it's not releasing the interior shift gear. Is the belt still spinning when you idle down? Just shooting out questions here for you to check.
Ill try that next. Any particular transmission oil? From the exterior part the detent is coming down about 3/8 of an inch. The rear brakes aren't working because I need new pads I believe. When I had the cover off the bellcrank I didn't notice anything moving inside when I pressed the brake? But from the exterior part it is coming down.
Sounds like the detent may be broken or badly gummed up, you can remove it and try shifting to see if that was the issue it just unscrews after you remove the spring. Polaris has specific trans oil I would use it.
I can unscrew the detent without remove the bell crank housing? If the detent is internally messed up inside the bell crank would unscrewing it from the outside still determine if the detent is the issue?? There's a spring on the inside of the bell crank for the detent as well right? Thanks Jon
The item that you unscrew from the outside is a stop with a pin that engages the shift gear to prevent it from going into park or high without stepping on the rear brake, it is not connected to the internal detent stop with the small 3/4" spring. Perhaps my terminology was not 100% and may have confused the issue. You can unscrew it without interfering with anything else to check if this was a problem.
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