I have a 1999 Polaris Sportsman 500 with 198 hours on it and it is hard to shift some times and grinds and once and a while it will pop out of gear. I also noticed last week when I checked my air filter that there was oil in the air box. Any ideas on what could be the cause of the hard shifting or the oil in the air box. I checked the belt and it looked good to me but, this is the first polaris atv that I have owned.

 

there is a guy on here old polaris tech.. find him and send him a pm or maybe he will see your post he know his ****... i have a 99 sp 500 also.. havnt had any oil in my air box or hard time shifting yet..

but isnt it fun pushing snow... i cant wait.. 95 degrees here in wisconsin today...

 

I have SP 500 H.O. / 2008, I don't know if it same like your.
There are two hose in the airbox. 1st from engine a 2nd from gear. I have oil in airbox after small accident, I turn up my sportsman and oil leaks to airbox. Check oil in engine and gearbox. If you don't turn up your, oil in airbox can be because you overfill engine or gearbox and excessive oil leaks to airbox. Excuse my english.

 

Always come to a complete stop before shifting and you should check the shifters linkage to make sure it is operating properly and engaging fully. Also make sure the transmission has the right amount and type of oil in it.

 

Oil gets into the air box through the crank vent hose if you over fill the oil,put the ATV on its side or even do alot of steep hill riding.

At idle give the shifter quick hard jerks,if that does not work take off your side panel and there are 2 shift rods you can adjust.

 

Thanks for the good information. I will look and see if the oil is overfull and also take a look at the shifting linkages. Bought the machine used and got an owners manual with it but, it is for three atv's and really does not have any detailed information about my specific atv. I was wondering if anyone knows of a site where you can download a pdf version of a good repair manual?

 

i have a 99 sportsman, and i am also having problems with mine shifting, if you put it in high gear it will kick out, i put new linkage on it adjusted it to spec, put in neutral had everything drop in place, run fine for about two minutes samething again, goes into high, hit the gas and take off out it pops, i have just about had all i can take of it, also, you may want to check your idle is right, if it is idleing high it will grind going into gear, please if anyone can, HELP ME