2002 Polaris 500 stuck in gear wont shift out of high or low
#1
#2
Common problem as the linkage ends and shift box components wear and get slack in them over the years.
Possible hydro lock on the gear shift box that many have done over the years from wear. Loosen the 10 mm lock nuts on the rod ends,remove the linkages from the gear shift box. Pop the gear shift into neutral,use vice grips on gear case belcranks and rock the atv back and forth until you can get the gear case into neutral. Check how much free play the shift lever has when the linkages are removed. If you have a lot of slack,adjustment may or may not help or may not last long.Adjust the rod ends in or out until they drop straight into the shift box levers with NO resistance.Then tighten the rod end lock nuts. Hopefully this can help.Plus again any wear items may need to be replaced if you notice a lot a of free play back and forth on the shift lever while it's in neural. A good fluid change wouldn't hurt also. 0w40/5w40 oil to where it barely covers the gear box shift levers.http://www.cyclepartswarehouse.com/f...2002&fveh=5582 Gears have to be fully engaged for the gear indicator switches on gear case to transmit the gear position to the speedo.Items 12,13. http://www.cyclepartswarehouse.com/f...2002&fveh=5582
Possible hydro lock on the gear shift box that many have done over the years from wear. Loosen the 10 mm lock nuts on the rod ends,remove the linkages from the gear shift box. Pop the gear shift into neutral,use vice grips on gear case belcranks and rock the atv back and forth until you can get the gear case into neutral. Check how much free play the shift lever has when the linkages are removed. If you have a lot of slack,adjustment may or may not help or may not last long.Adjust the rod ends in or out until they drop straight into the shift box levers with NO resistance.Then tighten the rod end lock nuts. Hopefully this can help.Plus again any wear items may need to be replaced if you notice a lot a of free play back and forth on the shift lever while it's in neural. A good fluid change wouldn't hurt also. 0w40/5w40 oil to where it barely covers the gear box shift levers.http://www.cyclepartswarehouse.com/f...2002&fveh=5582 Gears have to be fully engaged for the gear indicator switches on gear case to transmit the gear position to the speedo.Items 12,13. http://www.cyclepartswarehouse.com/f...2002&fveh=5582
Thread
Thread Starter
Forum
Replies
Last Post
Dakosk
Polaris Ask an Expert! In fond memory of Old Polaris Tech.
1
06-06-2015 05:37 PM
Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)