I have a polaris 600 sportsman that will not shift smoothly when the engine is on. When the engine is off it works fine, but on it is very hard if not impossible to shift. It's not any linkage. I think it has something to do with the belt or the clutch. Belt seems to look not worn... Maybe I need to rebuild the clutch but which one?? Do you think dropping the transmission fluid and changing it may help? I don't know where to start replacing parts...

Thanks!

 

Does it grind when you try to shift when it is running? It could be dirty or worn clutches and belt, and/or clutch alignment and broken engine/tranny mounts.

I would first start by cleaning the clutches good. Check the one way bearing on the primary clutch to make sure is turning freely. Look and see if the clutches look in line and inspect the motor and tranny mounts. Try it and see what happens. Those are the most common causes.

 

Clean clutches with pressurized air and replace the belt and I bet your problem dissappears.