07 Sportsman 800 shift problem.

[CASTnBLAST]

Only way I am able to shift is by shutting motor off. With motor off gear shift lever is smooth as new. Almost acts as idle is too high but doesn't seem any higher than normal and can't find any idle adjust being it's an EFI. Possibly a clutch issue since I get a bit of belt squeal when in gear at idle?

[Macgyver55]

More than likely a clutch problem. Drive clutch is most likely not releasing all the way. A good cleaning may take care of it unless you have worn bushings and such.

[eyehunter]

Idle adjustment is right on the throttle cabel between the throttle and speedo. It will have a rubber cover over it about 2" long, under that cover there is an adjustment screw type of thing, if you turn it one way it will reduce idle rpm and the opposite for the other way. Idle rpm should be around 1100 - 1200.

[CASTnBLAST]

Pulled the big plastic cover off the thumb throttle housing thinking that was the most sensible place to make an adjustment, will look further and try set idle down first. Kinda leaning towards the clutch needing a good cleaning though since one of my boys were last to use it. Post results when I get to it, thanks!

[aczr2k]

If the idle is fine, I think around 1050 rpms, more than likely it is the one way bearing on the primary clutch. Also check your motor mounts, there were some bad ones around those years, the rubber separates from the steel.

[fishing tech]

Worn belt. My 500 was doing the same thing. I replaced the belt and was good to go.

[CASTnBLAST]

Polaris dealer thought it was belt too but tried that to no avail. Seems to be a clutch problem to me, gave up and brought it in yesterday.

[PurpleFloyd]

Had that happen to a Polaris sportsman 500 that I bought. It was doing it nearly from the start but the dealer said there was nothing wrong. Once the warranty was over he figures out it was the clutch and didn't cover it under warranty even though I had it in under during the warranty period. It had only a few hundred miles on it to boot. The new clutch fixed the problem.

[NAMASafetyDirector]

Most of the time when this happens in the event all the other components of the clutch look fine, it's the spring in the drive clutch. The spring after a certain amount of time takes a set or becomes relaxed. At idle the spring doesn't have enough tension to keep the movable sheave from engaging the belt even at idle. You can easily see this is you take the clutch cover off and then start the engine. The sheaves may move over just a little but the clutch shouldn't actually be trying to engage the belt.

[CASTnBLAST]

Ended up being the drive clutch plates were cracking. About a $500 fix, ouch!