Quantcast
Jump to content

Recommended Posts

Posted

     I bought a 1996 Sportsman 500 4x4 about a month ago, and I love it. Unfortunately, I've been experiencing a few problems with the high-range gear. The first problem is that the gear selector will intermittently pop out of high and into neutral. This problem will sometimes occur when starting from a stop and sometimes will also occur while at cruising speed. The last time this happened I stopped and put it back into gear, however, as soon as I tried to throttle the machine would die. I turned it on again with no problems put it back into high and it died again. Once again I turned it on with no problems put it into low instead and it worked fine with no problem. I drove in low down the road slowly for a little and then shifted back into high with no issues. 

   I plan on working on it this weekend and would just like some opinions or feedback from anyone who may have experienced these problems before. I'm very mechanically inclined but im unsure of exactly where to start as this is the first Polaris ATV that I've owned. Any feedback is appreciated and thanks in advance :) 

Posted

Yup definitely check the shift adjustments.

It's strange it cuts out when it jumps out of gear. That might come right if the adjustment keeps it in gear. If the adjustment doesn't cure the jumping out problem and the gearbox needs work, then I'd try to figure what was causing the cutting out before I fixed the gears.

If, after adjusting the shift so it's moving fully into high, it still has he problem, it would be a good idea to take careful note of what the circumstances are causing it to jump out. There are some tests/observations to be made before stripping the gearbox.

  • Like 1
Posted
On 1/4/2025 at 12:46 PM, Mech said:

Yup definitely check the shift adjustments.

It's strange it cuts out when it jumps out of gear. That might come right if the adjustment keeps it in gear. If the adjustment doesn't cure the jumping out problem and the gearbox needs work, then I'd try to figure what was causing the cutting out before I fixed the gears.

If, after adjusting the shift so it's moving fully into high, it still has he problem, it would be a good idea to take careful note of what the circumstances are causing it to jump out. There are some tests/observations to be made before stripping the gearbox.

 

On 1/4/2025 at 1:06 AM, Gwbarm said:

I think the first thing i would check would be the shift linkage make sure its well oiled and moves freely it  could possibly need adjustment.

Ok, so I stripped it down this weekend in the garage and found some issues.

Number one was the gear selector itself,  I took that apart, and it was an absolute nightmare of rusty water, mud, and anything else you could imagine. I cleaned it out along with all of its small internals and put in new ATF fluid for the lubricant. It now moves freely and shifts smoothly. Time will tell if the internals will need to be replaced but as of right now, it's ok. 

Number two is the linkages that connect the selector to the transmission. The long one for both HI and Reverse had a considerable amount of washers on the end where the nut meets the tie rod. After loosening the nut and moving it back, I discovered that the washers were there because someone had stripped the threads on the rod. Due to this, I can't tighten the nut and properly adjust the rod. This makes sense as to why the shifter would occasionally pop out of high gear because it's not properly adjusted. I also discovered that the rod for the LOW gear is welded at the nut and the end rod. So I'm now either on the hunt for new/used linkages, or I may be able to re-thread the end of the rod.

Number three is that my driven clutch appears to be out of alignment. In neutral and at idle, the belt is sticking to the sheeve and constantly turning itself and the driven clutch. Due to this, I've ordered a real belt (Chinese one on it right now) and a package of shims to align the driven clutch properly. 

Still unsure of why it was dying in gear that time because it hasn't happened since however I'm assuming some combination of improper adjustment of both the shift linkages and the driven clutch was the reason. 

As I said this is the first Polaris ATV I've owned, and I'm new to the whole CVT transmission. Although it's a pain, it's still been a fun experience learning about these mechanisms. 

 

Posted

Glad it wasnt internal. You have been busy. Good diagnosis. It sounds like it has been ridden hard and jammed in and out of gear many times at some point in its life. I think it is repairable clean up the threads on the rod and it may work, but i would be tempted to look for a new shifter in good shape, you definately want to get it adjusted correctly so no internal damage happens. Hopefully the correct belt will solve your clutch problems also.

  • Like 1
Posted

"Still unsure of why it was dying in gear that time because it hasn't happened since however I'm assuming some combination of improper adjustment of both the shift linkages and the driven clutch was the reason. ".

The only think I could think of that would make it stall when it jumped out of high, was if it jumped into reverse. That would try to stall the engine if you were moving forwards at the time, but it shouldn't do it when you had just shifted and not got going, which I think was what you'd said it did sometimes, jumped out from an attempted start, but.. That , going into reverse, might stall the engine if the belt was driving as you are saying it does..  You'd think you'd have heard a clunk though if it was jumping into reverse.. So I assume it's not the case.. My best shot though.

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

  • Similar Forum Topics

    • By PIYIRIO
      Hi all - I recently had a shop fix this quad and it hasn't been right since. The jug was resealed as it was leaking, the rings were replaced, and the valve stem seals replaced. Shop said the cylinder walls were great so nothing was done there. The motor still smokes, heavily on startup and all but quits once warmed up. Enough that I can live with it if I can fix what I came to ask about. I mentioned this work because since I've gotten it back it seems like it has power but tops out at a much slower speed than before. It's old so I don't have a speedo but I pulled out my phone at it tops out at 25 mph. I know before the work, I was getting up to 45+ mph... It's so bad, my 10 year old daughter is pulling away and straight leaving me in the dust with her governed Polaris 90.
      Given the work done, what are some thing I could be the cause of such a drastic difference? I immediately thought timing but the marks appear to match up with a youtube video I found... no idea if it's correct though. It sat in another shop for 2 months and they gave me an $800 quote just for the starter... it pull starts fine. 
      FYI: I would take it back to the original shop to figure out but I had some issues that make them a no-go for me. 
    • By alain
      I just got this quad from my father in law need some tlc. Will need a new battery and does not know the battery PN as I don't have service manual. When my father in law had it , it uses lots of plugs, never got it service to verified why , he just buy an other plug and was good for a other 4 to 6 months .
      Any one would havd answers would be appreciated. Thanks
    • By mans
      Were is the neutral safety switch on 03' Kodiak 400 4x4 . How xan i check it to see if it's good for a no neutral light no power to machine. Ty
    • By Eisaks777
      hello, i have bpr bombaradier rally 200 2007 which has a lot of gasoline in the oil sump, it is  4 stroke. Has anybody had problem like this and which can be the cause and how to fix it. i rode it today at -2 degrees celcius if it helps.

    • By Snick
      Bought the project a few weeks ago with weak and intermittent spark. I could smack the CDI box with a screwdriver and it would work fine for a few days. Now, the smack trick is not working and machine is running awful with the weak spark and will most often not fire enough to turn the engine over through combustion (cranks very good). I ordered the GY6 CDI to see if I can get it going again as these CDI boxes are way too expensive even used. battery is fully charged and charging very good.
       
      Wondering if anyone knows how the GY6 (6-pin AC) CDI would wire to this machine. Attached is the electrical diagram. My confusion is with the green and orange wires sharing the 2-pin connector and the Blk/Red wire that runs to the magneto solo. How would I get AC power to the CDI through pin 1 on the GY6 when the CDI has two wires to the pickup-myabe just try one (orange then green) at a time?
       
       
       


       
      ^PINOUT:
            5   6
            2   4
           1    3
×
×
  • Create New...