I am new to the forums, but not new to ATV's, rode my friends machines occasionally and finally decided to take the plunge with this project.
The story:
3100 km 497 hrs on machine, factory winch and work lights, green plastics.
Advertised as a 2005 but was built in late November 2005 and I can't find a 2005 500 with EFI but there is a 2006 500 EFI. It is a Canadian model if that makes a difference, is that what is referred to as an International model when looking up parts?
Just bought this yesterday, knowing that the seller did disclose a noise at higher speeds beforehand but tried to tell me it was just the belt, so as it happens there was a brand new Polaris drive belt included in the sale, apparently he hoped I would take his word, go home, change belt and all good... right?
So I go for a very short test ride, noticed that the trans would make the noise when in high gear taking off from a stop with light throttle application. Low gear fine, reverse fine, rolls easily in neutral, and park holds.
I said " I'll change the belt here and now, and if it still pops out its not the belt is it?" He agreed (sort of) and I changed the belt, which took about half an hour start to finish, (thanks Youtube) most of that time messing with the cover and vent ducting going back together, it's sure a lot easier to replace the belt on a sled!
So belt changed, trans still does same thing. I am not surprised. I pull the trans drain plug, there's oil but its a little dark. I mention the cost of a new trans and the likelihood of selling the machine to anyone else in its condition.
I buy it for a very good price, take it home and start researching. Haven't torn into it yet. I think its either worn dogs on the high gear, or the high/reverse engagement dog. Possibly a bent high/reverse shift fork or damaged groove in the shift drum where the high/reverse shift fork contacts it.
Without tear down I won't know for sure, but could a very loose final drive chain/worn tensioner shoe also give the same symptoms? I just am not sure if the chain would skip in high range but not low range. All the other gears seem to work properly.
Priced out the gear and engagement dog, about $200.
Is it common for these parts to fail at such a low mileage?
Thanks for your time.