There’s no good time for your gear to slip into neutral, especially if you’re driving a Polaris RZR at high speeds. Therefore, if your gear keeps slipping, you should determine why and try to fix it immediately. Unfortunately, it can be tricky to determine the cause and even trickier to fix.
If your Polaris RZR gear keeps slipping, you should determine which part of the transmission is failing and adjust the parts accordingly. The issue is often with the shift drum, cable, clutches, or drive belt.
In the rest of this article, I’ll explain some common reasons for a Polaris RZR gear slipping. I’ll also discuss how to fix the problems so you can avoid having this issue in the future and get back to driving your Polaris RZR worry-free.
Causes and Fixes of Slipping Polaris RZR Gear
Something is wrong if your gears are shifting without you doing it yourself. Let’s look at some potential causes of this issue and how to fix them.
You Need To Replace the Shift Drum in Your Transmission
One possible cause of your gear slipping on a Polaris RZR is a problem with the shift drum. The shift drum is an essential part of the transmission component of any motorized vehicle, as this is the part that moves the shift forks and changes the gear. Therefore, if there is a problem with the shift drum, you’re likely to experience your gear slipping or shifting without your participation (source).
To check if this is the issue:
- Look at the shift drum and inspect it for signs of wear and damage.
- If you need to replace the part, lift on the shift rail and move the assembly to fit within the drum.
- Install the fork ends into the drum (source).
The forks must be in the correct position in the drum. If they aren’t, your gear will likely continue slipping.
I recommend taking a picture of your transmission before removing or adjusting parts so you can replicate it when you’re putting everything back together. If you don’t feel comfortable replacing or fixing the shift drum, you can always go to a mechanic for help.
For more information about the RZR transmission and how to work with a shift drum, check out this YouTube video on the topic:
Your Shift Selector Cable Is Failing
Your gear slipping could indicate that your vehicle’s selector cable is failing. Other symptoms of this problem are if your vehicle starts in a gear other than neutral or if your gear selector refuses to move (source).
If your shift selector cable is old, damaged, or falling apart, you’ll need to replace it with a new one. I recommend this Quad Logic RZR Shift Cable (link to Amazon). This shift cable is an exact replacement for the Polaris RZR-4 1000 and the Turbo 4-1000, but it fits many RZR models. I also like that it is made in the United States.
Once you have the new cable, replacement is a relatively straightforward process of using wrenches to remove the old cable and installing the new one, ensuring that all the parts are securely connected.
For a more detailed guide on how to replace a shift cable, check out the following YouTube video:
The Main and Secondary Clutches Aren’t Aligned
If your clutches aren’t aligned, you’ll likely experience problems with the gear slipping in your Polaris RZR. This is a likely problem because the clutches can easily get knocked out of place while driving on rough terrain.
To align your clutches, you’ll need a clutch alignment tool. I recommend this TOMMARS Clutch Alignment Tool Kit (link to Amazon) because it is suitable for many vehicles, including a Polaris RZR. I also like that the screw action allows for quick adjustment and the spigot adaptors help with close alignment.
Once you have this tool, align the clutches by following these steps:
- Jack up your RZR.
- Remove the wheel.
- Take off the suspension and the clutch cover.
- Remove the belt.
- Take off the secondary clutch and the primary clutch.
- Remove the clutch cover.
- Loosen the necessary bolts.
- Align your shafts.
- Torque the bolts.
- Replace the inner clutch cover, then replace the secondary and primary clutches.
- Put the belt back on.
Once the clutches are aligned, you’re unlikely to experience the problem of your gear slipping again.
Your Drive Belt Needs To Be Replaced
The drive belt in a Polaris RZR can heat up and deteriorate, which causes a plethora of issues, including gear slipping. Luckily, it is a relatively easy part to replace.
First, you’ll need to acquire a new drive belt. I recommend this SuperATV Badass CVT Drive Belt (link to Amazon). This belt is compatible with all Polaris RZRs after 2014, and it is built specifically for intense riding, so your gear is unlikely to slip with this belt. I like that the belt can handle more than 10,000 pounds (4,536 kg)of tension without breaking.
Once you have your new belt, it’s time to install it. Follow the following steps:
- Access the belt by removing the air duct using a flex drive tool.
- Remove the screws in the clutch cover and move the cover out of the way.
- Remove the old belt by spreading the clutch sheets apart on the clutch and loosening the tension.
- Clean the clutch of any debris or old belt pieces that may be stuck on them.
- Blow off as much dust as possible.
- Place the belt on the clutch using a belt installation tool.
- Clean the inside of your clutch cover.
- Install the clutch cover and tighten the screws.
Once you’ve replaced the belt, your Polaris RZR should work well, and you can confidently hit the road.
If your Polaris RZR Gear indicator is not working, fixing it is not hard. Read my other guide to learn how.
Final Thoughts
If your Polaris RZR gear keeps slipping, the problem is likely with the shift drum, shift cable, clutches, or drive belt. The best way to fix the issue is to check these parts and replace any that look damaged or worn down. You can often make these fixes yourself, but if you aren’t confident in your ability to do so, you can seek a mechanic’s help.
