I just bought a 2004 Sportsman 700 twin with 502 miles and 72 hours on it. There is no High gear. When in High gear it just grinds and pops out of gear. The Low and Reverse work great. Has anyone had this problem before and is it a common thing? Any ideas what it is? I haven't taken it to the dealer yet but I'm betting it's going to be some big bucks. Thanks in advance.

 

My first guess is that it is just a shift linkage adjustment issue. Push the shift lever all the way forward to the "high" position. you might have to give it a quick firm motion.....this is normal. Once you are satisfied that the shifter is all the way forward. Disconnect the shift linkage rod from the little actuator arm on the transmission. Get a 12 inch adjustable wrench or something similar, and use it to try to move the actuator a little bit more forward, past where the shifting lever left it. You need to use your head here, and not apply so much force that you destroy it. that being said, you want to put enough force on it to ensure that it is all the way engaged. Now that that's done, jump on and give it a test ride.......

 

if the adjustment does not fix your problem, then the tranny has to come out. there are gears with engagement dogs on them, dogs are probably worn round..
this is fronm somebody shifting from 1 gear to another while it was still moving.
the gear is about 100$.
could also be 2 gears in the shifter box on side of trans, trans removal not required for this, they are about 30$ each. good luck