1996 Polaris Sportsman 500 4x4 Issues with high gear

[Sportsman500guy]

     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  

[Gwbarm]

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.

[Mech]

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.

[Sportsman500guy]

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. 

 

[Gwbarm]

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.

[Mech]

"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.

[Sportsman500guy]

On 1/5/2025 at 7:18 PM, Gwbarm said:

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.

 

On 1/5/2025 at 11:12 PM, Mech said:

"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.

Ok so I figured I would follow up and let you guys know what’s been going on. I’ve definitely been getting busy with the ole quad. I ended up replacing the shift rods because they were both to far gone. Along with that I put on a new belt and a new clutch on it. With both of those working properly I no longer have had any issues with it jumping out of gear into neutral. Since the day it wanted to died on me it hasn’t happened since and everything has been running right. 

I bought the quad off of an older gentleman so I think at the end of his ownership maintenance had been neglected which is totally understandable due to his age. After I did the rod and clutch work I’ve also replaced tie rods, brake pads, the starter, fuel filter, pull starter and I popped off the fly wheel and cleaned that entire area because it was full of rusty water. So far it’s been running great and starting no problem even in the cold weather.

Although as you could imagine some of the work has been greasy and a bit of a pain I’ve definitely enjoyed learning and working on this Polaris machine. As I said I figured I’d follow up with you guys and let you know what was going on. Along with that I wanted to say thank you for your suggestions and tips about what could be the problem with it. Cheers guys, thanks again! 

 

[Mech]

Good news.. Have fun on it..

[Gwbarm]

Thanks for the update, its always good to hear success stories. You have been busy and did a lot of work, glad you got it going. Excellent work!

[johniii]

Congratulations, ride on!!