Hello all. A newbie here with a few Polaris questions.

I have a 99 Sportsman 4X4 that I use to plow snow with here in Upstate NY. We finally got our first plowable snow and I hit my first snow pile and the beast gets stuck. I never had an issue with this last year?? So I attempt to put it into reverse and it is a no go. I can not move the lever back? After a few extra attempts I get the lever to move a little and find that the gears are spinning and now I can't get it back into gear without the grinding of metal to metal!!! I am assuming my 4 wheel drive is not working as well since I got stuck so easily. I took the shift module off and cleaned it up along with adding more fluid to the resi. When I had it in my had it seemed to work just fine. I then bolted the shift lever back on and I could get High and reverse but no low. With a screw driver I could get it to shift into gears I believe since the lights would indicate it but it could have just been touching the sensor.

I am thinking maybe it could be a misaligned clutch which is putting pressure on the gears to keep them spinning hence not being able to put it into gear without grinding. But what about the lever not wanting to go in any direction now??? I can't get it out of high and into reverse without holding the lever back with my hand??? Also 4 wheel doesn't seem to work?

I did blow a belt this summer and things havn't seemed to be right since. If it is a misaligned clutch, is it something I can do in the garage or would it be better to take it to a mechanic? Not sure how to do a realignment but don't want to get ripped off taking it to a shop.

Any suggestions would be greatly appreciated!!

Thanks in advanced,
Pete

 

hello pede,welcome to the forum.if you blew a belt and it has not been well since,i would open up the belt cover and inspect.your secondary pully should not be spinning much if at all.i have smooth engagement of f=r=n.when i first start mine the right pully does not spin at all,after a few engagements it might spin extremely slow,maybe 1 revolution a second then stop after a minute.if your secondary is spinning even a couple revs a second that could get you a grinding.look at belt well for wear+look around for pieces of old belt no matter how small.be extremely careful of primary clutch!wear safety glasses,keep fingers away when running.....

 

make sure you are not idled too high as well. chances are by the sounds the linkage is out of ajustment or a bent shifting fork inside the trans. you shouldnt have to hold or reef the bike into any gear under pressure. should be eay to see if the awd is working or not in snow by seeing if the rear wheels spin easily.