My 1996 Sportsman 400 (2 stroke) is now unshiftable when it gets warm. Drive it for 100 yards, and it will no longer come out of gear, much less go into another gear. This machine has been bullet proof so far.
What is going on with it, and is it a big repair???

Thanks to you all.
BB

 

[QUOTE=Neptugian;3028449]My 1996 Sportsman 400 (2 stroke) is now unshiftable when it gets warm. Drive it for 100 yards, and it will no longer come out of gear, much less go into another gear. This machine has been bullet proof so far.
What is going on with it, and is it a big repair???

Thanks to you all.
BB[/QUO

Try changing trans fluid first ?. You can also try to adjust linkage (PLENTY of posts on this) But the early shifters would eventually wear out and parts replacement and frustration on these shift boxes just isn't worth it at times! I just replaced a lot of shifter assemblies! You can try to adjust linkage:First make sure trans levers(bell cranks are tight and linkage ends are tight also. Place in neutral(manually with vice grips if have to!) Loosen 10 mm lock nuts on both linkage arms that go into shift box levers,then remove both linkage arms from shift box,check for sloppy play in shift lever,if excessive,adjustment may not help much. Turn the small linkage joints to where they both just drop straight in shifter levers,tighten the lock nuts, and replace the two nuts securing linkage to box. This may or may not help shift better?? The 96 model has the improved shift forks and gears (recalls were on 94 models to update internal trans parts) BUT has the same old shifter! You can tear shift box apart,but most parts that wear are shift levers,pivot ball on shifter lever,etc. If you don't have a manual or parts break down,you can look up your model on PURE POLARIS PARTS and see whats involved. Newer straight line shifters were a welcome improvement,but can't be used on yours. Some of the shift parts are NLA and complete shifter on Cheap Cycle parts retails for 329 dollars,cheaper than dealers,but check other sources. OPT

 

Thank YOu!!!!!

 

The idle didn't go really high did?