Dont know much about polaris~ 2002 500 sportsman
Wont change gears, suck in N
Will it start in gear?
Should I be able to change gears when not running?
checked linkage to tran.case, tryed holding brake???

 

Mine did this and it was the motor mount being lose causing the linkage and tranny to bind. It could also be a bent sift fork. It should shift when not running and yes they can start in gear.

 

Thanks for the reply, I can't get the big pulley off the belt rides on. I'm scared I'm going to brake it or bend it.
I feel it shouldn't be that hard to get off!
I'm looking at the shifter fork being in a bind or bent??? If I can ever get case out of frame to break down!!

 

you should be able to get your belt off the secondary (b.pulley) then the one bolt holds the clutch on a spline to the shaft. pretty much just slides off. you may have to spray some bp blaster to break some rust or corr. maybe w/ a rubber hammer tap on the back side to slide it off.

 

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My '04 stuck in reverse last week. I disconnected one linkage pin in the middle so I could wiggle the shifter box linkage better. That worked. No problem since. Something in the shifter box must have been mis-aligned.

GJRonK

 

The other week , I took the belt off and bolt out of pulley, tried rubber hammer and a bar to put pressure on it. I couldn't get it to move? So , I got this big??fly wheel Remover? tried it and while tapping it with a rubber hammer and felt like I was going to damage it!

I will go buy some Pb blaster and put wheeler on its side, spray it and let it set over night.
Thanks

 

Thanks, I let that bp blaster set on there few days, and put that puller on it , it came right off!!!

The tran looks simple to remove but it say, " make sure I unhook switches before dissemble and resemble" anyone know, what switches they are talking about"?

 

maybe a couple or wire harnesses from the gear selector sensor should be able to see them i would think unsure though w/out looking.