I was plowing yesterday with my 500 Sportsman with a 60" plow and noticed on several occasions that it was very difficult to change gears. A couple of times I had to pull so hard that I was afraid that I would break the shift lever. Any thoughts or suggestions?

 

The shifting on both my XP's is difficult ....not as hard as JSR describes but I would also like to know if this is normal or if there is a trick to it.

 

ruggo, you are only a stones throw away. I live in Framingham

 

just up the road .....

 

your photos say that you ride the power lines have you registered your bikes in MA? So far, I only ride on private property in Hopkinton so I haven't bothered yet

 

I just bought the 2 XP's and the kids 660 Raptor and TRX 400 EX and I planned on registering them today. I'm a procrastinator so maybe tomorrow or by the end of week. I figure at least if they are register and we got in trouble for being on the power lines having the taxes paid on all of them and registered would help.

 

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

I was plowing yesterday with my 500 Sportsman with a 60" plow and noticed on several occasions that it was very difficult to change gears. A couple of times I had to pull so hard that I was afraid that I would break the shift lever. Any thoughts or suggestions?</end quote></div>


It could be, depending on the year, that the gear-selector box is loose where it mounts to the frame.

It could also be related to a high idle speed.

I would look at those things first. Next would be the clutch...

 

JSRIII-Like said a high idle is a common cause for hard shifting..what is the idle speed? Is it higher that normal? Clutch alignment can cause it as well..if it is one of those issues it will normally try to creep in gear,especially on a hard flat or downhill surface...
Other possiblities are the shifter mount and linkage like jchunn said..
As well as internal transmission damage...

Ruggo-the Sportsman shifter detents are pretty stiff,especially when new..it will get a little easier as it breaks in...
I lubed the shfiter mount bushing,linkage pivot points and and also the lever on the tranny itslef and it helped noticably....but the trick IMO is to kind of bump it into gear with your palm instead of trying to push it in..just be careful going into high and park so as not to put too much stress on the linkage by forcing it against the stops..once you get the hang of "bumping" it into each gear it's pretty easy..

 

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

I was plowing yesterday with my 500 Sportsman with a 60" plow and noticed on several occasions that it was very difficult to change gears. A couple of times I had to pull so hard that I was afraid that I would break the shift lever. Any thoughts or suggestions?</end quote></div>

Mine was shifting fairly hard a while back. Turns out I just needed to change the belt. Take the cover off first, and see if you secondary clutch is spinning during idle. It shouldn't be.

 

mine shifted hard from plowing. but i figured out it was from haveing ths choke on, and it was in high idle. after i took the choke of it was fine.