Hello,

I bought a 96 sportsman 400 a couple of weeks ago. Most of the time it is hard to shift into low gear, I kinda have to jiggle the shifter a couple of times to get it to go in. I don't have to press the brake to shift. Tonight while plowing snow it got to the point where it wouldn't go into low gear at all. I turned the atv off for a while and got back on it. It started to shift really smoothly into low for a while then stopped shifting into the gear altogether. I got a little annoyed and tried to push it in with my foot. BAD MOVE, DUMB A$$. I shifted it into high and the *** came out of the pattern and moved really close to the machine. Now it doesn't shift at all. It is in high gear. There was no creep before when the machine was in gear.

I drove it under the shed and removed the exhaust cover and the exhaust, to access the gear selector. When I press the slides it looks like either water or oil is leaking around them. Is there supposed to be oil in he unit?

I think that when I kicked it I broke something and I am going to have to tear it apart to rebuild it. It looks like it is going to be really hard to take off. I might have to pull the belt cover to access the back of it from the other side.

Has anyone ever done a rebuild on this before. I live in valdez alaska, the closest polaris shop is at least 250 miles, so that is a last resort. Do they sell rebuild kits or do I just have to tear it apart to see what is broke. I don't have a shop manual, or an owners manual for that matter. Anyone have a good recemendation on one.

Is it ok to move the transmission into neutral from directly on the transmission where the bar connects from the gear selector.

i searched the forum and read a bunch of posts, that is what go me to this point. I really appreciate everyones help.

 

Don't know about the inner workings of the shifter. It does sound as though you hurt it pretty good. I have a shifter and rods off a 94 400 4x4 I believe will work. I think shipping to AK would be spendy though. Doc

 

sent you a pm

I didn't really even push it that hard.

Oh well, I just put the plow on it yesterday and used it for a couple of hours before it broke. I really need to get it fixed before we get more snow, which will be tonight or tomorrow. Oh well, that life I guess. I pulled up a parts schematic on the inernet and it looks kinda complicated, with springs and such.

 

not that hard to fix you broke a pin that goes all the way accros the shift box to line up the shifter can weld or poss replace with rool pin.. your shiter was just out of adajment to start un doo the to tierod ends on the shifter that go to the trans.(make sure in nutral first) pull the bolts around the top of shifter housing 4or5 of them then just pull up on the shift lever it will come right out then u will se the cross shaft you broke emal me i will give pohne # to call me i can type sr spell for sh%^ ADVPOWERSP@aol.com

 

not bad idea to clean the shifter housing out and change the oil.But the shifter has to work for the AWD to work.

 

<div class="FTQUOTE"><begin quote>Originally posted by: ftwflh

not bad idea to clean the shifter housing out and change the oil.But the shifter has to work for the AWD to work.</end quote></div>

what kind of oil should I use?

 

You can use 30 weight or multi weight just dont overfill. Fill to where shift arms are covered,but not up too high on oil level.

 

I hate to keep asking all these questions but thanks for the help.

 

Better to ask questions than go into something blind! Usually someone has already encountered your same problem and you can learn from their experience. Good luck

 

e mail me for ph# i will tell u how to by pass shifter switch verry simple do it too all my cost. machins that got some time on them.