Transmission Service - Troubleshooting - Polaris Magnum 2x4 Service Manual

TRANSMISSION SERVICE
Troubleshooting
If shifting difficulty is still encountered after adjustment, per-
form the following steps:
1 . Disconnect shift rods from transmission bellcrank.
Check torque required to move bellcrank (should be 10
ft. Ibs.). Select gear and
hold 10ft. Ibs. torque on
bel/crank.
Roll machine in the opposite direction of the
gear selected (roll machine backward if a forward gear
is selected - roll machine forward if reverse is selected).
NOTE:
Be sure to hold torque on bellcrank while rolling
until the transmission gears are fully engaged.
2. Start machine and test ride. If transmission operation is
satisfactory during the test ride, the shifting problem is
outside
the transmission. Check travel of the shift
selector slides, re-check transmission adjustment,
fasteners, torque stop, etc.
• Travel of shift selector slides should be
.600/1 (15.2
mm) full movement, or
.300"
(7.6 mm) one way.
Troubleshooting
Check the following items when shifting difficulty is encountered.
• Transmission oil type/quality
• Torque stop adjustment
• Loose fasteners on rod ends
• Loose fasteners on selector box
• Worn rod ends, clevis pins, or pivot arm bushings
• Linkage rod adjustment and rod end positioning
• Shift selector rail travel
• *Worn, broken or damaged internal transmission components
*NOTE:
To determine if shifting difficulty or problem is caused by an internal transmission problem, isolate the
transmission by disconnecting linkage rods from transmission bellcranks. Manually select each gear range using
the procedure in Step 1 above, and test ride vehicle. If it functions properly, the problem is outside the transmis-
sion. Refer to troubleshooting checklist above.
7/96 8.6
Polaris Industries Inc.