I need some help.We have a 2003 sportsman 700 that doesn't want to go into high range unless you rock the machine back and forth.If you don't rock it and just put it in it grinds.It will go into any other gear exept high and then when it does go into high sometimes it pops back out.It is not in the linkage and when I took off the side cover that the shaft goes through everything looked great,no mud or rust.This all started after the epi clutch was put in with the "big spring" the one that doesn't engage until high rpm's.We have changed the spring to the milder one but no luck.Thinking this is internal..Any advise--Thanks

 

It sounds like your clutches are maybe staying engaged and keeping the trans spinning while you are trying to shift. Does it do it in all gears? What's your idle at??? Maybe pull the clutch cover off and see if the primary is spinning the secondary. Check belt deflection (I"m not sure how) Hope this helps.

 

Belt deflection is checked by holding a stright edge along the belt and apply the recomended pressure and if should fall in the specs in the service manual......Don't have these numbers for the sportsamn yet....My manual is on the way!!!!!!!!!!...Caper.....

 

Hello--Thanks for the advice.I ran it with the cover off and the clutches are stopping.I talked to a "polaris mech." and he said to split the case and see if the snapring that holds the gear cluster tight didn't pop off,or maybe a shift fork wore down.All the other gears work fine and the idle actually should be turned up a little.I guess I will have to break into it.

 

maybe the shift fork is bent. that would be a my guess.

 

how does it shift with the motor OFF?

 

When it is off the only way to get high to engage is to rock the machine back and forth and if you shift to low,park etc.. they all engage correct but when you put it back in high it just doesn't engage without the back and forth rocking of machine...I'll be tearing it apart tomorrow and see whats inside.

 

Inside your transmission is what you call dogs they are a gear that spline into a another gear on a shaft. In my experience working at a dealer i see a lot of gears worn down, what happens is after a period of time putting in high gear when the machine in not completely still wears them out. the reason it goes in when you rock it is because where you have worn the gear down the end is larger and it want let the sincronizers guide it in. In other words the small tappered end has gotted bigger and it harder to line up the gears. the reason it is poping out of gear is because there is not enough gear meshed into the other gear and pressure pops it out. when you tear it down make sure a shifting fork is not bent or wore becase not pushing teh dog gear a full srtoke will also cause wear on the gear.