I can not shift gears if the bike is running, if engine is off it shifts fine. I removed the linkage, trans switch and sector cover I remove all gears and lubed them and reinstalled everything. The bellcrank was replaced because it was bent and the gear was tore up a bit. And it didn't fix anying. I have looked at a lot of posts on here and read the manual and I'm stuck.
Also there is no adjustment for the linkage or bellcrank ????

 

Did you check the belt/clutch? I know when the belt started shredding years back on my 02 700 the shift lever didn't function properly.

 

I just took the primary clutch off and and pulled it apart and cleaned it, I also just rebuilt the secondary clutch, and i installed a new oem belt. Any other ideas????

 

when running in gear does it try to pull

 

The bike was creeping before I rebuilt the secondary clutch, but the rebuild fixed it.

 

What is your idle set at? If it is at all close to were the clutchs are starting to engage it wont shift. Try turning idle down a little see if it helps. Does it shift ok when the motor is not running?

 

The bike is a efi so there is no idle as far as I know, I did a resistance test on the idle air control, it tested out fine, even swaped it out off of a different throttle body. In N it idle is about 1200rpm in gear is about 1150 rpm. The bike changes gears just fine if the engine is not running.

 

1200 rpms is to fast my sportsman you cant change the gears if its running that fast should be able to slow it down

 

My 07 sp500 EFI idles at 1150-1200 and shifts very smoothly and clutch engages about 1350. Does your quad have EBS? Maybe the one way bearing on the primary is dragging or seized?

 

Is there any way to check it, I pulled the cover off and started the bike and if I rev up the bike the primary moves in and out just like it should. ????And yes it has EBS