I had to take my ATV in for the 2nd time in a month and a half b/c it is stuck in high, last time it was stuck in low. Anyone else had this problem.

 

Mine was stuck in reverse, twice, and it went back to the dealer, twice. In fact, on the first time, I had to ride out of the trail two miles in reverse. The dealer finally replaced the shifter box, but I wonder if it really had anything wrong with it because those things are really simple mechanisms. After researching the subject on this forum, I found that a stuck shifter is a pretty common problem on the Sportsmans. If the linkage rods are out of adjustment, it can easily become stuck in gear.

A few days ago, I went out for a ride, and that thing was sticking in Low. I finally took apart the shift box (mine is a 2003 model with the 'h' pattern). I had no idea what to expect, but what I found was a very simple design. The box is filled with 10W40 motor oil. After removing the top, I soaked the oil up into a rag, and then looked at the two rods that go into the box. Inside the box, each rod has a notch in it to accommodate the shift lever. When the transmission is in neutral, the notches are perfectly side by side. With the transmission in neutral (you can disconnect the linkage and push it into neutral by hand, if necessary), adjust the linkage rods so that those two notches are perfectly adjacent to one another. This should give you the perfect adjustment. My machine has never had such a positive feel when engaging gears as it does now. This job took me 15 minutes total.

If your machine is a 2004, then disregard everything I just said because you have the new shift pattern, and I have no idea how that one works. However, someone else just posted the same problem on a new Sportsman. Check back a few days ago if this applies to you.

 

Wilecoyote said it right. I might add to re-fill the shifter box with oil to just cover the shifter rods. Motor oil is fine.

Farmr

 

It's an 03. An the guy at the dealer told me I was getting water in there and that's what cause it this time.

 

Getting water in where? Inside the transmission? Given how common this problem is, I would be skeptical about that explanation.

 

water inside the shifter box

water doesnt get in the tranny unless your above the seat