Fixing Polaris shifter

In this video here ‪@montemania198210‬ I show how to easily fix a stuck or frozen shifter on your polaris. This shifter design was used on almost every polaris atv equipped with a low range for almost 3 decades. below is list of models that use this style shifter.
Model List
Magnum 325, 330, 500
Sportsman 335, 500
Xplorer 250, 400, 500
Xpress 300
Big Boss 500

[@danielgray2978]

Thanks for great step by step instructional video!!

[@FuzzyOso1]

Thank you for this. I bought a 2000 Sportsman and after a couple days playing, there was fluid on the foot rest. The gear selector was the only place I could figure it was coming from. This video confirmed that yes, there is fluid in there. Replace the o-rings today and will have some fun this weekend to see if it leaks any longer.

[@montemania198210]

You are very welcome.

[@thomasimmesberger2644]

Thanks. Great video very informative. I’m glad I’m not the only one dropping things lol .

[@HexiledRazz]

Clear, concise and to-the-point. If only every diassembly video was as good as yours!

[@montemania198210]

Thank you sir.

[@lyouden]

Thanks man. Educational and entertaining!

[@tommykid29]

I’ve got a 2003 Sportsman 500, and my gearshift got stuck plowing snow. I followed your instructions and this project went very smooth. I wish more videos were like this, because you explained all of the pitfalls and exactly how the parts were supposed to fit back together. Thanks again for helping me keep my sanity.

[@shanewise7625]

Man I've got a 2004 Polaris Sportsman and the exact same thing. Plowing snow and got stuck in reverse. Going to try this. Wish me luck! LOL

[@shanewise7625]

Thank you for the video, going to try it

[@73elperro]

Good video,thank you for sharing your knowledge!!

[@Norton3139]

Excellent video. Doing mine now thanks to your video.

[@jeffanhorn]

Went through a few 425 video Polaris and this popped up. Weekend project now.

[@patrickgronlund8577]

Thank You. I bought a 2001 Magnum 325 5 years ago and it never shifted into low. Found your video, did what you did, now it works like new.

[@montemania198210]

Great to hear!

[@tomjohnston7980]

Hi Pat. So when you took it apart what was causing the shifting problem?

[@patrickgronlund8577]

The plunger for low gear with the o-rings was rusted.

[@jandeband]

What did you fix, mine is real sloppy, is there a rebuild kit ?

[@patrickgronlund8577]

Low gear plunger was stuck. Cleaned/removed all the rust. Don't know about a rebuild kit.

[@abreubrian819]

I wanna say thanks this video SAVED ME HUNDREDS OF DOLLARS and it's like NEW 👍

[@brianyemen]

Thanks for posting.

[@jeffanderson8885]

Awesome video man. Thank you!

[@mwbjgamingprojects]

Thanks for your video, I'll use this as a go-along to help me service mine, I just bought a 1997 Polaris Magnum 425 6x6 and it needs a lot of work. I liked and subscribed to your channel.

[@KN-sd9lt]

great video. thank you for sharing

[@ejr4140]

this video just saved me alot of money !! thanks bro

[@montemania198210]

That’s why i do these lol. Glad it helped

[@larryniidji]

Excellent! Thank you.

[@mainecoastcustoms2324]

THANKS! Just fixed my wife’s 300, shifts smooth now!

[@donaldshank7899]

Great video!!

[@montemania198210]

Thanks for the visit

[@carlrpmmotoplus]

Y'oure my man dude !!!

[@Norton3139]

Thank you!

[@unsaltedlife5998]

I had 2 little springs and 2 larger ones in my 94 425 magnum 4x4

[@brucegreen1016]

hey good video, looks simple enough. two questions, first what if the pin lock is stuck and wont fall out when tapped on and the other is, what's better to use ATF or grease in the housing. i have a 1995 400 4x4 xplorer. shifter acting up after plowing

[@airdronenorway]

I filled the whole housing with grease, works good :)

[@Juan0000]

Sempre das muy buem informacion sobre polaris. Gracias

[@kmvl797]

Thanks! Same problem on my Linhai 400 ATV. I think it hade water that freezed... Janne , Sweden

[@user-lo9ro5pn2k]

Great video. We tore ours apart yesterday and put it back together. It instantly locked up again. What are we missing?

[@dnprgp0]

Will this do the trick on a shifter that is extremely sloppy? I have a 96 xplorer and I try to go forward and reverse but have to rock the quad back in forth to get it to go in gear because of the extra slop in the shifter itself

[@QuantumOfSolace1]

We wielded the damn - now it never breaks the pin!

[@therealmtsinai]

Question: I have a 2001 sportsman 500 ho that i use for plowing, it has a heck of a time getting in gear makes the zzzzz sound trying to shift in all gears, it seems like something is worn out. Any idea what that could be?

[@markhanson798]

Mine just did that and then the shifter arm snap completely off hopefully I can weld it back together

[@cm5838]

If only, I’ve been fighting this one for two days, soaked for 24 hours in rust remover.

[@jandeband]

Ive got a sloppy shifter, on my recently acquired , 99 sportsman 500, easy fix, rebuild or replace ?

[@travisalder9360]

How many o rings on each plunger? Are they different sizes?

[@jandeband]

How do you replace the boot, 99 polaris, sportsman 500 ?

[@DeanTheBean12]

were do i buy a polaris shifter for my 400 explorer

[@Amanda-xl9xy]

Hey there, thanks for the time you spent making this content to help others. Say, you wouldn't have any tips for a stop pin that won't come out? I've been tapping, then rapping, then smacking this thing against my concrete floor to no avail. I soaked overnight in PBlaster, still no dice. I have the whole housing in the freezer right now thinking some thermal changes might help loosen the pin. I've tapped on it using a punch and a hammer (light, rapid taps) hoping to vibrate it loose but still nothing. I've tried moving the selector slides to different positions to see if that will help, too, but nothing. EDIT: For anyone reading this, I was able to get the pin out using MAPP gas and heating it. Propane wouldn't cut it. Drilling seemed impossible, even with cobalt bits.

[@montemania198210]

Thanks for the comment. So these roll pins are a nightmare. Usually if it doesn't come out I just drill them out.

[@Amanda-xl9xy]

@@montemania198210 Thanks for the reply, that may be what has to happen. I was able to find replacements available online so if I can't get the pin out intact by the time a replacement arrives, out comes the drill.

[@montemania198210]

@@Amanda-xl9xy also you don't have to use a pin can use a nut and bolt. Much easier to take apart next time.

[@Amanda-xl9xy]

@@montemania198210 I sure hope there wouldn't be a next time! I'm working on an '01 ranger 6x6, the pin is completely recessed within the casing in this model, not sure I could use a nut and bolt, but I could of course cut a bolt to fit if i couldn't source a pin.

[@BerettaVandy]

any suggestions on getting the large pin out that prevents the slotted plungers the shifting rods attach too? pin doesn't wanna come out

[@jedimaster2023]

I got that same problem I even put oil down into the ball pin holes and filled it all the way up and let it soak and still can't get it to come out

[@jimrucker5726]

Going to attack today. I just dont have a new boot but have one on order. TKX Good Vid 👍

[@Trucksfourwehelersthreewheeler]

Could I get the dimensions of that small spring I lost mine and can’t find it

[@curtisbaker7538]

What size are the o-rings on the plungers? Will I only need two?

[@Robertfishes62]

I do not know the sizes..but it takes 4 o-rings total, 2 different thicknesses.

[@tomjohnston7980]

Thanks for the video. Was out plowing and was having trouble shifting. It works part of the time but gets stuck in a gear after a while. If I take a screwdriver I can move the selector to the correct position so I can shift. Does this sound like a problem inside this box? I see parts are available but waiting to see if that's the problem. 2001 Polaris Sportsman 500 HO

[@montemania198210]

More then likely it is in shifter box. I’ve repaired more then I can count. Also on some sportsman’s one of the shift link rods go to a pivot point. That tends to seize up, take it apart and grease.

[@tomjohnston7980]

@@montemania198210 OK thanks. I didn't inspect the other end but will make sure it's greased. Looks easy enough to inspect. The spring tip was helpful also when taking apart. It would have probably flown out into the garage somewhere.

[@lucascoburn4323]

Did this fix your issue? Mine is having the same issue. I'm trying this in the morning. Got a 96 sportsman 500 reviving it. Gotta drain front and rear diff and refill as well as new break pads and bleed the brakes and then we are done besides visual parts.

[@mattshields6561]

I have a 2000 500 and the dowel pin will not come out. Did you grind the top of it?

[@Amanda-xl9xy]

I've got the same problem, did you find a fix for getting that pin out?

[@kylemclaughlin9140]

I can’t seem to remove to the lock pin. Tapping it on the table and with a rubber mallet it doesn’t budge. Any suggestions?

[@montemania198210]

Soak it in Penetrating oil

[@garyjohn316]

How did you remove linkage rods from shifter???? Thanks!

[@montemania198210]

Just under the ball and socket you put a wrench to hold it while using a socket to remove the nut.

[@garyjohn316]

@@montemania198210 Got it off cleaned and installed thanks to you!

[@dondadda2011]

How did you get the linkage off..

[@garyjohn316]

I used a small pair of needle nose vice grips. Right above the nut that you are trying to remove is shaft , right below the washer squeeze in the vice grips and it will hold it from spinning while you are un tightening the nut. Hope this helps

[@normdepeel3937]

i just throw some grease on that little spring to hold it in place

[@lorettacaputo6997]

Would this cause a machine not to go completely into reverse? I have a finicky reverse gear. I have adjusted the shifter rods.

[@montemania198210]

It very wheel could. Or u have a internal issue in transmission. Best thing to do is take shift linkage off transmission and try to manually engage reverse. If I goes in reverse then it’s definitely in shifter

[@lorettacaputo6997]

@@montemania198210 That has been in my mind for a while. Interestingly, the going into reverse usually only happens after the machine has been running for 20 minutes or so and of course during snow plowing when I am frequently going from forward to reverse. I will especially see the failure to go into reverse or come out of reverse if the machine is tipped forward on an incline.

[@Kingsoupturbo]

@@lorettacaputo6997 I have the same issue with mine, I recently stripped down the transmission and found nothing wrong, its got to be the shifter as I did the rods too. When it gets real warm, its not happy, or maybe its incline, hmmmm.

[@lorettacaputo6997]

@@Kingsoupturbo When you took the gear box apart did you notice any wear to the shift fork or the high reverse dog engagement gear? I find it odd that everyone who has this problem seems to temporarily solve it by slight adjustments to the shift rods. I am also thinking that the wear play in the shift shaft that comes out of the top of the gear box may be a culprit. I look for any play in the whole system.

[@Kingsoupturbo]

@@lorettacaputo6997 Its pretty interesting really. There was almost no wear to the Shift Dog, and just tiny chipping on the high gear, yet I could not for the life of me, get this thing to engage smoothly reverse and high at the same time (low always worked great) The shift fork is barley worn, there is almost no metal in the case, I expected to find a real problem in there. The case has shift detents in the bottom to hold the fork in gear, all seemed fine on mine and the detents on the shifter seem fine too, so the hell if I know what this fidgity polaris system wants from me. Next is the shifter box taking apart, I read from old polaris Tech, on the forums, 90% of the time its the shift box, so lets see if hes right, not much to go wrong in the trans but she grinds like a SOB if the moon and the stars aren't aligned.

[@cheeseball247]

Does this fix a floppy shifter?? What would cause it to be so loose when In gear?

[@montemania198210]

Loose shifter is usually due to the end joints on linkage being worn out. Their like mini tie rods.

[@cheeseball247]

@@montemania198210 I’ve checked the end joints, all 4. They’re tight. Seems to be inside that shifter box.

[@montemania198210]

@@cheeseball247 it’s possible, I have seen worn out pins and worn shift rod due to corrosion. You’ll have to take it apart and investigate.

[@jandeband]

Can yu rebuild the shifter ?

[@perrylund4889]

Do you have to change the oil in this?

[@montemania198210]

Their “sealed for life” “maintenance free”. Lol I’ve done this on over 200 shifters in my day. If it’s working fine I’d leave it alone though. No need to change the oil if it’s working properly

[@perrylund4889]

@@montemania198210 ok,was just curious cause my gears grind when putting it in high, or reverse.

[@montemania198210]

Gears grinding is due to high idle causing secondary clutch to spin at idle. Try lowering your idle speed of engine.