Hello, I have a 1994 polaris big boss 400. Been through the ringer. I have been looking for a shift box assembly, not having any luck from the usual sources. A piece of casting is broken on shift box so I am unable to repair. I am still able to use hi gear, attempted to adjust to gain use of reverse, which is intermittent at best. Low gear is locked due to broken casting. I use this atv only for plowing on my property and dragging firewood. I disconnected the shift linkage and was able to positively engage reverse, neutral, high and low geas using bell cranks and pliers. Has anyone bypassed the shift box assembly and fabricated simple levers for shifting or would this be a bad idea or not work due to sensor on shift box. Thanks for your time. Nate

 

Best to get a used on ebay,less trouble in the long run.Used shift boxes are not cheap,but you have to run the shift switch directly to the terminal board to get awd if you changed the shift system. Constant power to the hub coils just causes more wear and tear and causes armature plates to magnetize quicker.Plus internal parts are still available to rebuild the shift boxes.You can check this site out for parts,plus still lists the box separately(item 18) but no guarantee that they have them. Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

I have searched ebay, but haven't had much luck. I haven't found any info on part # that superceded 1341164 shift box. I overlooked that the housing was still available. I will go that route and rebuild. Thanks for your reply.

 

Might want to get this while it's still available.Polaris Pure ATV Gear Selector Body 3233082 | eBay

 

Thanks for finding that OPT, a NOS one popped up on craigslist, complete for 46 dollars that I picked up last night. Do you have any tips for separating exhaust that is rusted together, or would it be wise to just take all the plastic off and remove as one unit? Then I will have to make sure I do the linkage adjustment correctly. Factor service manual was a little confusin.

 

Just pull the springs and tap the exhaust at the front. Pull the spring at the back and just loosen the nut enough to where the muffler slides over the carriage bolt head and away from the mount.

 

So I replaced the shift assembly with a new unit, shifts into all gears as it should now, but now awd does not work. I simply swapped unit out with existing shift sensor, is their any calibraton needed or do I just have a dud.

 

No calibration as most of the time the shift lever ball doesn't hit the plunger in the shift switch especially in high range and if you just transferred old worn parts to the new shift box. You can push a little forward on the lever and see if the awd lights up.Try low range also and see if awd works,usually does as it's used less often. You can get a new high $ switch and replace worn parts or do as some have done. Box switch has a gray/white,brown,purple and red/white that plug into the circuit board into their respective slots.Some have placed the gray/white(forward awd wire) to the red/white section which powers up the awd when the key is on and in gear. Same thing on the purple(reverse) wire. More wear on the awd parts over time as it's always "engaged" ready for the front wheels to kick in when the rear wheels slip. Just one way to bypass the switch. Plus I think some have gone from the awd switch itself to the red/white to eliminate the box switch entirely.

 

Thanks for the reply. The box that I put on was one that a guy had purchased and never installed, came with new switch or sensor. I'll look around for the switch, if no luck I will try and bypass as stated. If I do bypass will the awd button still work to disengage awd or would I have permanent awd? If so I could add a simple toggle switch to turn off?

 

Haven't done it myself,but if you jump the switch box wires directly to the red/white(powered when key is on) then don't think the awd switch can turn it off.Either that or install the new switch that came with the shift box and do it right. Plus if any worn shift box parts are needed,get them now before they become NLA...