my 94 sportsman 400 4x4 stalls immediately every time i try to put it in reverse - it runs fine in low (high has its own issue - just won't engage at all - ratchets when try to shift into high). Trying to tackle one problem at a time, just got bike 2 weeks ago & both reverse & high worked ok. Main issue is not having reverse, anyone have an idea of why the motor would just cut out every time it is put in reverse? doesn't matter if engine is warmed or cold, it just stalls hard every time i shift into reverse. seeminly nothing to do with the 4x4 button, have tried with & without the 4x4 engaged. Looking for answer to reverse problem but will also take any gouge on the high gear issue as well.....

 

Find the black wire coming from the reverse limiter and follow it to the wire block and unplug it.

 

thanks for the reply-don't have the service manual yet, just owners manual & it sucks, where is the reverse limiter located, if you can help....

 

It is a little box with 3 wires and 1 is black.It should be on the front around the inside of the bumper area

 

try adjusting your shift linkage to get in hi..my 400 has 2 rods if you follow the shifter down...you may need to lengthen the one for your hi gear...

 

On the high issue you most likely need to replace the bellcrank.It is the lever that the shift rod hooks into.They strip out.You may be able to tighten it a little.

 

thanks for the help to all...the overide switch is somehow the source of the reverse issue, it will go in reverse now but only if you push & hod the override button the whole time, gonna get it on lift & find that damn box/wire & disconnect it, hopefully that will fix it & can just thro it in reverse w/out holding button.

the hi issue i will look at today too- i had guessed maybe bellcrank but am hoping an adjustment will get it in gear, need to see if it can be adjusted, that would be sweet....thanks.

 

Just take off tank plastic,disconnect black wire at top of terminal board as noted above,kill switch wire there also! Is trans grinding in fwd or reverse? Hope not,94's had problem with pinned shift forks(positive fwd,grinding reverse,or vise versa) Replace several under warranty with new kit where shift forks were milled out of solid bar stock. Hope its just the limiter you are talking about!

 

thanks, i will try it that way, what tank plastic? the whole tank? I finally have a day to find that wire.... Yeah, it just dies when shifted to reverse but when I try to put in high, it ratchets & wont go into high gear. low works fine.

 

just the tank cover if its a 94 model and side panels, Terminal board on left hand side,black wire terminals at top! Also you can try to adjust linkage,sometimes this may help, if not, disconnect linkage for hi-n-r at trans if you can and see if manually can shift it with vice grips on belcrank (shift arm on trans),if still grinding shift fork problem! 94's had "TEAM TIPS" bulletin was not a voluntary recall,some ok, some developed problems.