Hello all, I have a 1995 Polaris Sportsman 400. Seemed to be running well, I go out and get on it, and now I have only reverse! I have no forward gears at all, I can move it only in reverse which seems to be fine! This is the first atv I have ever owned so I am at a loss as to where to begin to figure it out. Does anyone have any ideas that might do the trick? Or atleast get me on the right track to getting it back to moving forward without having to push it? Any help is appreciated!

 

Welcome! 90% of the time it's a linkage adjustment problem,shift box problem or both! First off place the shift lever in neutral. If it's frozen look at the aluminum belcranks(shift levers) on the gear case and use vice grip if needed to manually get into neutral. Loosen the 10 mm nuts at the ball ends of both linkage rods at the shift box,then remove the 10 mm nuts holding the linkage arms to the shift box and remove the linkage arms. Check for excess slack in the shift lever box now. If it has a LOT of slack back and forth on the lever(before either shift lever moves), linkage adjustment may not help or will just be a temporary fix! While shift lever is still in neutral turn the linkage ball ends to where they line up straight with the holes in the shift box levers,insert linkage ends,tighten ball end lock nuts and replace the two 10 mm nuts. See if you have forward and reverse now. If it grinds trying to go in gear or jumps out of gear,the shift box needs to be replaced! I've tried to repair boxes before and it's cheaper just to replace them as all the parts needed to repair cost as much as the box,plus your time. This is a very common problem on this style shift box(until they went to the straight line shifter boxes) and I replaced many of em. Try this place out if you need to order a shift box(comes complete with gear position switch) Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse OR http://www.cheapcycleparts.com/makes/3-polaris/years to see if the complete box is still available or NLA,then you would have to replace the worn parts individually.
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Hi, and thank you so much for your reply! I just had a chance to take a look at it this evening and I found that the linkage rod has came apart where it ties into the shifter box, and when it came apart, it was in reverse. So I guess I will now get a new linkage rod and try to get it on and all adjusted. Is there an easy way to get to it? I have the exhaust pipe in my way! Any other suggestions would be great if you have any. Hoping I can get this part pretty soon and get it back going before too long. My kids are ready! Would you replace just the one or would you replace them both while I'm at it? Thanks again for your reply and I appreciate your response in advance!

 

If only one linkage rod is damaged,the shift levers on the gear case are ok and the ball ends on the other rod don't have a lot of slack, you can get by just replacing the one linkage. Make sure you still adjust both linkage arms while shifter is in neutral. As far as clearance to work on it,it's not that hard to pull the muffler out of the way if need to. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Look here on your model under "gear shifter" to show the linkage,rod ends and cost. Cheaper here than most dealers. Hope this solves the problem and you can still use the gear shift box. OPT