Polaris RANGER 1000 2020, Service Manual

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9850045 R01 - 2020-2021 RANGER 1000 Service Manual
© Copyright Polaris Inc.
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TRANSMISSION DIAGNOSTICS
HARD SHIFTING
SYSTEM DIAGNOSIS
Difficulty shifting, or harsh shifting are generally caused by the Transmission or PVT Systems. The system causing the
difficult shifting concern can generally be diagnosed using the following information.
SYMPTOM CAUSE
Vehicle is difficult to shift ONLY with the engine running Refer to PVT System Chapter for more information
Vehicle is difficult to shift all the time Refer to Transmission Isolation this will help determine
if the concern is internal or external to the transmission.
After isolation proceed with diagnosis.
ADDITIONAL HARD SHIFTING CAUSES
SHIFTING CAUSES
• Shift cable adjustment/condition
• PVT alignment (clutch center distance)
• Transmission lubricant type/quality
• Transmission leaks / fluid level
• Loose fasteners on sector gear cover
• Worn rod ends, clevis pins, or pivot arm bushings
• Shift selector rail travel
• Worn, broken or damaged internal transmission
components
TRANSMISSION ISOLATION
To determine if shifting difficulty or problem is caused by an internal transmission problem or external concern the
transmission should be isolated using the following information.
After the transmission is isolated refer to Additional Shifting Causes or the proper chapter in the service manual for
additional information.
1. Disconnect the shift cable from the bellcrank.
2. With the shift cable disconnected from the transmission shift the vehicle using the shift lever.
• If the shift lever continues to bind the concern is likely caused by the shift cable. Refer to the proper service
information for replacement.
• If the shift lever moves freely proceed to step 3.
3. With the shift lever disconnected manually select each gear range at the transmission bellcrank.
• If the bellcrank requires more than approximately 15 ft-lbs (20 N·m) to rotate, the shifting concern is most likely
caused by an internal transmission concern.
• If the bellcrank moves freely, manually select each gear range at the transmission bellcrank and test ride vehicle.
If it functions properly then there is likely still an outside concern causing the issue.
GENERAL INFORMATION
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