stuck in gear
#1
hey there guys! im trying to figure out why the hell my 03,sportsman,500,ho,4x4... keeps getting stuck in gear?? i took the cover off and checked the clutch belt everything looks good except when i pull and push on the clutch wheel it looks like the spring is losing its tension!! and it also is rolling foward or reverse when its in gear.. i took it all apart yesterday cleaned everything pretty good and blew it out with my compressor! im thinking it might need a clutch but im not sure how to go about see if the clutch is bad without getting hit with a dealers cost to tell me whats wrong with it!!! and there just going to tell me it could be this or that and a couple hours later and didnt even work on it!!!!!!!!!!
now its stuck in gear and it so hard to get out i took it all apart even the rods and i can take it out of gear like that sometimes it shifts ok other time i cant get the thing out of gear!! if any 1 can help me out here i would really appreciate it thanks jeff!!!!!!!!!!!!!!!!!!!!:

now its stuck in gear and it so hard to get out i took it all apart even the rods and i can take it out of gear like that sometimes it shifts ok other time i cant get the thing out of gear!! if any 1 can help me out here i would really appreciate it thanks jeff!!!!!!!!!!!!!!!!!!!!:


#2
Several things to check especially if it's creeping in gear. The belt must be riding in the center of the one way bearing in the front clutch and NOT touching either side of the front clutch sheaths. Check this while in neural with the cover off and at an idle. If the belt isn't centered,you may have to add/remove shims behind rear rear clutch to align the belt properly. Item #2
Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Also the front clutch one way bearing has a fiber washer and brass washer that when worn can cause problems. You have to have a clutch tool and spider tool to replace these.Item #2 and 18.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Also linkage adjustment may be needed. Have the machine in neutral. Loosen the 10mm linkage lock nuts on the ball ends at the shift box, then remove the lock nuts holding the linkage arms to the box. Turn the ball ends to where they drop STRAIGHT in the shift levers with NO resistance. Then tighten the linkage lock nuts and replace the 10 mm nuts on the shift levers. Look at the belt also for any burnt/glazed sections,replace if badly worn. This can help a lot of the time.
Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Also the front clutch one way bearing has a fiber washer and brass washer that when worn can cause problems. You have to have a clutch tool and spider tool to replace these.Item #2 and 18.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Also linkage adjustment may be needed. Have the machine in neutral. Loosen the 10mm linkage lock nuts on the ball ends at the shift box, then remove the lock nuts holding the linkage arms to the box. Turn the ball ends to where they drop STRAIGHT in the shift levers with NO resistance. Then tighten the linkage lock nuts and replace the 10 mm nuts on the shift levers. Look at the belt also for any burnt/glazed sections,replace if badly worn. This can help a lot of the time.
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