Polaris Sportsman 600 high gear not engaging

This video shows you a likely cause for why your Polaris sportsman is grinding while trying to shift into high gear.

[@tonygoecke3906]

I have a Polaris 330 ATP with this same problem after 400 hours of use. Rather than replace the gear, I ground the 90 degree flat back into the gear, It worked great for about another 75 hours of use. My suspicion is this the gear wear is caused by the gears not engaging in deep enough. I am going to add a shim between the press fit gear and the drive gear to increase the engagement depth of the gears. The root cause of this issue is it is a very poor design. From the post I look at, it looks like this problem persist with Polaris transmissions from 2004 through 2012. I wonder if they came up with a fix or continued with this design throughout current production.

[@Dieselequipmentparts]

I found this true on a 2005 polaris ranger 6x6 that after replaceing the second high gear engagement dog, i found that the dogs were only engageing 60%, dropped it off at my local machine and they resurface the dog and machined off behind the idler gear as much as they could without making the needle bearing run off the its race, then added a shim behind the press fit gear, that allowed the dog to fully engage gear. And they were able to resurface the engagement gear. All for less than half price of a new gear!

[@faye50291]

Hi ,do you have to take the tanny right to do is

[@Deerector]

Awesome vid. Thanks. How about the clunk that a lot of Sportsmans have when taking off? You hear thank clunk only when hitting throttle. Usually from a standstill. Happens in reverse too.

[@luvmygarage7184]

Deerector dude all the polaris do that. The reason is because of the belt drive system. The tranny does not engage until the rpms get high enough to engage the belt. So there is a little "jerk" when that happens. Nothing you can do about it.

[@Deerector]

luvmygarage I def hear it on lots of them but for instance my buddies is real loud and mine is real low. So what would we do get his somewhat more normal (quieter)

[@timgile8144]

usually things cause that, - not waiting to put in gear until stopped and - not pushing foot brake -idle is to high

[@lh98]

your issue was the grinding when putting the selector into high gear or it happened (grinded) when you pushed the throttle after already selecting high gear? I ask because my 700 grinds sometimes when i accelerate in Low gear but my brothers 600 grinds almost every time when hitting the throttle in High gear.

[@luvmygarage7184]

Yes and yes. My gear was definitely worn out. I know some other people have offered suggestions as to why I was having this problem. With all due respect to them, I was having this problem because my gear was worn out. :-)

[@torihilyard8969]

Hi, could you put a part number by chance?

[@j33p74]

Hey bro what is the name of gear that you replaced? How did you order it? I have a 700 but if I was a gambling man Id say its the same on both engines.

[@luvmygarage7184]

j33p74 I took the old gear to the Polaris dealership and they told me the new gear to buy. I never wrote down the actual part number. I just know I got it from Polaris. My bet would also be that it is the same as the 700.

[@j33p74]

luvmygarage I kinda want to avoid dealer prices but I think I'm gonna have to suck it up.

[@nathanmitchell5508]

I got a question my Polaris 400 will go into gear but she won’t move now I imagine something is locked up but yeah it will go in every gear just fine but won’t move not the breaks I kno for sure checked any help would be much appreciated thank you.

[@lh98]

Nathan Mitchell did u figure out what was wrong?

[@ramonapatombon1203]

how to full out the high gear?

[@sethmoses7768]

Know the name of that gear??

[@luvmygarage7184]

It is just the high gear for that 2004 sportsman.

[@johnabelljr1997]

Dude! Learn to record your videos in landscape and not in portrait