I have a 2005 Polaris Sportsman 500 HO with less then 80 miles and 60 hours on it. When in low gear and taking a sharp left turn the gears grind loudly. They also grind briefly when rapidly accelerating in low gear. When I took it in, they dismantled the gear box and found the engagement dogs for low gear were chipped (I have a picture). The service technician of course blamed me for improper shifting. I owned a 400 Polaris for years and never rode or shifted any differently. I also do not remember ever shifting unless at a complete stop and low rpm. Of course I am out of warranty. Has anyone else experience this situation and did Polaris stand behind their product?

 

welcome to the forum. i havent read or did i have any problem w/ my old 500. and some times i didnt come to a complete stop from low to high. sounds like a fluke thing.