Hello,

Whilst out riding today, had to do a 3 point turn on a narrow track. After going from reverse back to high, the gearbox would not engage.

After moving the selector forward and backwards a few times, reverse would engage whether in neutral, low or high.

After several attempts, the gearbox engaged with the selector at high, but gearbox appeared to be in low range.

Also when braking the gearbox disengaged and after several attempts managed to get it into low range whist the selector on high.

When I loaded it on the trailer, only would engage in low, no matter whether selector was in high, low, neutral or reverse.

I checked oil levels, linkages which appeared ok.

The display for L, N & H, were still corresponding to the gear selector position but gears not engaging.

Any suggestions as to what problem would be would be appreciated.

Regards

Mike

 

First thing I'd check is that the shift lever (belcrank) hasn't stripped it's splines. Made out of aluminum and designed to give way normally before other parts do. If it's still tight on the shift shaft,then possibly could be damage to the small teeth on the internal gear selector.Didn't have the chance to tear a 550 down,but hope it's not a major problem that you have to. Item #17,item #10. Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Thanks Old Polaris Tech,

You've confirmed what I thought the problem might be as shafts are turning and linkages all appear tight.

I'll take a pic once I've pulled it apart.

 

Got the gearbox stripped down and found the problem.


The pin on the fork shifter had sheered off (item 15 on parts list).


Had a good look through the rest of the box, everything else looks good. Fortunately pin had sheered clean off and was sitting in one piece in the bottom of the case.


Any idea if this is a common problem or what might have caused it. I would have thought the aluminium bellcrank would have stripped first.


The only one that rides the quad is my wife so it's hard to imagine that brute strength would have snapped the pin. I'm worried that their could be something more sinister going on

 

Not a common problem,at least not with all the other Polaris transmissions I've ever worked on. In fact I've never had one shear a shift fork pin over the years. Probably just a bad heat treatment or just a fluke break.I'd look at the bright side that this was all that it was and you were lucky compared to others that have transmission problems.

 

Thanks OPT,


Got parts on order, should take & 2 weeks to get to Aus. The waiting is the worst part.


Very clean break.

 

Just a bad casting or mill job. Wish all the problems I had were as simple as this!