We just got 10+ inches of snow today and I worked the sportsman hard. Using reverse and low forward, the shift lever is klunking more that normal as I shift between the two gears. I tried reducing the idle speed and that helped a bit. My question is what can I do to get a smoother shift? It's always been hard shifting and klunking in each and every gear. The polaris mechanic said it's normal. Today my buddy came by in his sportsman 500 and the shifting is smooth. Any assistance will be appreciated.

 

It will clunk when you change between forward and reverse, its how it works, it won't hurt it and all of us with twins have to deal with it. The 500 had a different rear differential, the 500 is has a one piece clutch gearbox and rear diff, the twins have a seperate trans gear box and rear diff with a shaft inbetween. the 500 is a different animal than the 700/800. The initial clunk you hear is the trans ingauging the proper gear into action, and it happens each time you change ranges, low high and reverse.

Good luck. [img]i/expressions/face-icon-small-smile.gif[/img]