My 2004 Polaris 600 Twin Sportsman is having it's first issue since new. Low gear has no problems. Switching to High gear switches as it should but once you take off, the grinding happens and the quad doesn't want to move. It will move but grinds not wanting to. Any ideas of the issue?

Thank you,
Blake

 

If low works fine but the problem starts when in high it sounds like a Belt/Clutch or Transmission problem.
First thing i would do is remove the belt cover and inspect the belt and clutch.

 

Nomicron99, thank you for your advice. I pulled off the clutch cover and noticed a little debris inside. I decided to remove the belt since I had an extra one on hand. Upon inspecting, I couldn't find anything broken from the outside. I did notice that when the secondary clutch is manually turned that I could hear debris floating around inside. I'm thinking something broke off inside, obviously. I'm going to watch some YouTube channels to see if it's something I can handle. Do you have any more advice?

Thank you,
Blake

 

That's always hard to answer. Whats your mechanical ability?
If you believe it is inside the transmission they are really not complicated at all and fixing it yourself is is probably possible as long as you understand how to use a wrench and torque wrench your probably good to go.
Not much on YT about these transmissions. Find a manual and fallow the procedures they outline for a tear down and reassembly.
If your sure its the transmission and not willing to do that type of work there are a couple on EBay or you might try a recycle place such as Recycled Cycles in Hayden Idaho. Might be one near you where you live i don't know.

 

I can turned a wrench but will take me more time than most as I'm slow to make sure I don't miss anything. One question, the debris I hear when turning the secondary clutch are actually floating around inside the secondary clutch. Does this make sense? I'm not sure if it's the transmission because of this.

 

Yes there are some things in it that can give you a problem for sure. One way bearing to name one.

 

This might help you out.
https://www.cheapcycleparts.com/oemp.../driven-clutch

 

Great. I may just find a new or used one to throw on it. Seems like that may be the easiest route to take and just hope it works.

 

Thank you, yes it does.

 

The number 2 part for $489.99, could something break inside? Inside is where I hear the debris floating around when manually turned?