How to synchronize gears on a 1999 polaris sportsman 500 4×4

 

Think I've answered this quite a few times.Make sure the trans levers(belcranks) are tight and rod ends aren't worn out. Have the shifter in neutral,loosen the 10 mm lock nuts on the rod ends at the shift box levers. Remove the 10mm nuts holding the linkage arms to the gear shift box. At this time check for excessive forward and rear play at the shift box lever. If it has a good deal of free play,adjustment may or may not help,but may help for a while. Turn the rod ends to where they drop straight into the shift levers with NO pressure on the levers. Tighten the rod end lock nuts,then replace the two 10 mm nuts holding the rod ends to the shift box levers. You should be able to get a positive forward,reverse and low gear position after this. If you don't,you may need to replace any worn rod ends plus any worn parts in the gear shift box itself. Some parts are starting to become NLA on certain models. Here's the break down of all the parts involved.Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse