Last week I put a new chain on our 1996 xplorer 300. Did it the way the manual said got the slack set between a 1/4 to 1/2 inch.

Never had a problem with grinding the the gears trying to put it into high side before. Does not do it all the time just once in awhile. Seems like if you don't get it locked into gear it will pop out it has done that maybe 5 times it happens when you just start out. If you get it locked in I don't have any problem with it.

I went back and did some searching in the forum and it looks like I can adjust the linkage if that is the problem. But wanted to post on here to see if anyone else thinks it could be the linkage out of wack since I put the new chain on. Could it be something else?

The chain that was on it was supposed to be new when I bought it but it was stretched and couldn't get it to adjust correctly.

I just about got all the little bugs worked out of this explorer 300 and it seems to run great but it also seems that when I fix one thing I find that something else is wrong. But I think there is light at the end of the tunnel I really do believe that once I get it to shift into high grear correctly I might have the last bug out of it at least for awhile.

 

You have to preload the suspension on the older Polaris.Take a tie strap to the rear rack and hitch.tighten it but not real tight.Now adjust the chain to specs.
I bet the chain is too tight.It will lok looose until you set on the bike then it will still seem a little loose.But when you ride and hit bumps it will be ok.Too tight you will mess up axle bearings,tranny output bearing and snap chains.

 

That is what I did When I put the new chain on. I did it by the book. But I will check to make sure I have the 1/4 to 1/2 inch play in the chain like the manual says to.

 

Check the shift arms on the tranny(bell cranks) they tend to strip out and even loosen up in time.Then check the linkages for adjustment.If all else fails take the top off the shifter ,clean and inspect refill with 30wt oil.