Just bought one for $400. Engine cranks and runs great. Now for the problem list. No Low range and no Reverse!!! 4X4 does not activate as well.

Reverse being the the biggie as I can live without 4X4 and low range if i have too. High Range forward is great though. So as long as I'm going the right direction all is good. Probaby will not be taking any cross country rides on this quad, but will be using it to get some work done on the deer farm, and maybe work our local hare scramble with it in a couple months. We always need a couple paddy wagons to ferry the wounded and broke down from the trails back to the parking lot.

I tried to look up a few posts on these quads and read everyone saying to leave them alone, but it ran so good I though I would give it a shot and take a chance it's fixable without to much $$$. I'm gonna try to hunt up a service manual on it, but in the meantime anyone got any quick troubleshooting steps or ideas on getting reverse going on this quad?

Get some pics tomorrow as well so everyone can see it.

 

Generally the transmission is screwed. But the first step would be to disconnect both linkage rods, and put the transmission and the shifter in neutral the reconnect the rods. Making any adjustments to the rods at that time. Then see what you've got. Good luck Doc Where are you from? And welcome

 

I'm' from Tallahassee FL. The previous owner had already removed the low range linkage piece from the shifter/transmission. I have the rod and was gonna maybe play around with it and see if there is any hope the tranny is not toast. Like I said it runs great in high forward. Just no Low or Reverse. Can't even get the shifter to go into Reverse and the low range shifter linkage arm is disconnected. I figure if I'm real lucky just the linkage is screwed up and maybe I can at least get reverse back and maybe even low range. Worst case tranny is toast and needs rebuild. If I can get parts online fairly cheap for that I will and rebuild it myself.
I have a bud that's a master mechanic on these things, but I hate to bug him unless I get completely stuck cause his time is valuable too.
If someone has a service manual out there I can download let me know. I found a paper clymers manual online I will probably end up getting, but sometimes those manuals leave out quit a bit of steps when troubleshooting and don't have a ton of detail on stuff like the transmission. They just assume if its broken you will be replacing with a new one. Which in this case will probably not happen unless a good cheap one shows up on ebay or somewhere.
These ATV's are like dirt bikes and PWC's. Once they get past a certain age they are basically not worth fixing anymore and get junked or parted out.

 

Thought I had it and got lucky. Pulled the shifter linkage rods off the box and still could not shift low range and the high and reverse were very hard to engage. Shot some PB Blaster in the shifter mechanism and started working with it and it got smoother and smoother even the low range that would not even shift at all before.

Put the main linkage arm back on crossed my fingers, but NO GO for reverse still. Can't pull it that gear at all. High range shifted smooth. Will test low range later. Reverse is priority now.

Anyone got any suggestions on reverse and that gearbox and how to troubleshoot test it. What would cause you not to be able to at least pull it in that gear? Gearbox shot or is there something else to try first before pulling it out?

 

If you have the shifter working, they will come apart and have oil in them. To adjust rods correctly, put tranny in nuetral, disconnect both ends and adjust so the ends line up with the holes perfectly straight, if it wont adjust, the shift dogs in the tranny are worn, you have to remove the tranny and split the case, you can buy the parts to repair it, might want the service manual for this job.

 

It is adjusted OK and without the tranny hooked up to the linkage the shifter pulls all the way into Reverse. Just can't pull the tranny into Reverse. Just will not go. Starts to pull it in gets about 1/2 way and thats it, and I'm pulling it pretty hard. It does not engage Reverse at all. Don't want to get too rough with it and break something in the linkage or shifter arm assembly.
Definitely a tranny problem.

 

With the linkage adjusted properly I can't shift properly into forward or reverse. When I try forward high range the tranny just clicks like it's trying to engage, but never does. Can't even pull reverse period. If I put the linkage way off to the high range side it will engage forward high range.

My question is can the tranny be fixed or is it better to find one that works if I can? Also any idea what it would cost parts wise? Almost would rather fix what I have if I can. Then I know what I have and can trust it. Instead of gambling on one I don't know about and end up in the same boat or worst.

 

TRanny is simple to fix once it is out of the frame.Sounds like you need at least shift forks and silent chain

 

Got one off ebay for $350. Hope it's good. Looks clean.
POLARIS MAGNUM 425 TRANSMISSION ASSEMBLY 4X4:eBay Motors (item 330352161475 end time Aug-20-09 18:30:42 PDT)
A little more than I wanted to pay, but I got the quad cheap so it's not that bad.

 

any time you get a tranny take it apart and replace the silent chain and check the internals.I didnt once and had to pull it out and fix reverse.These trannys are very simple.
Hardest thing is taking them out and putting them in