Shift lever is floppy - Honda ATV Forum
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post #1 of 10 (permalink) Old 09-21-2010, 12:36 PM Thread Starter
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Shift lever is floppy

The shift lever on my Rancher 360 is floppy. Started to hit the footpeg frame and shifting gears cannot be achieved. I put a piece of alumimum can "strip" before to shim it. It worked for a while till the alumimum wore out. Will it hurt to tack-weld the shifter to the transmission shaft? Is there anything in the trans. that will be damaged by the heat? I will put a wet rag on the shaft to reduce the heat. I can grind off the tack if any disassembley is needed. Is there a "traditional" fix? It seems the splines on the trans. shaft are gone, if there ever were any. Thanks.
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post #2 of 10 (permalink) Old 09-21-2010, 01:21 PM
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If the splines on the shift shaft are gone, there's no way to fix it other than replacing the shift shaft and foot shifter or welding it, like you mentioned.

I've seen them welded, just keep a wet rag around the shaft, close to the engine, like you said. Take your time, if you let it get too hot, it will melt the shaft seal.

Most 4-wheeler problems are caused by a loose nut connecting the handlebars and the seat!!

You only need two tools in life -- WD-40 and duct tape. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape.
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post #3 of 10 (permalink) Old 09-21-2010, 01:55 PM Thread Starter
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Thanks for the reply... How big of a job is it to replace the shift shaft?
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post #4 of 10 (permalink) Old 09-21-2010, 02:11 PM
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Thanks for the reply... How big of a job is it to replace the shift shaft?
You have to remove the rear crankcase cover and then there's a bolt that holds it in. The hardest part is getting to the rear crankcase cover to remove it. Probably easier to just remove the engine and then take it apart.

Most 4-wheeler problems are caused by a loose nut connecting the handlebars and the seat!!

You only need two tools in life -- WD-40 and duct tape. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape.
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post #5 of 10 (permalink) Old 09-22-2010, 08:40 AM Thread Starter
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I pulled the lever off. The splines on the shift shaft are still good. The splines on the lever are shot. I used a lever from an ATC 200 for temporary use. It fits very nice and tight. I was able to use it to chase down some wild goats. The geometry isn't right but it "worked". I will get a new lever when I get to town. Thanks for the help. A "police manuavr" worked good on the goats at about 25mph. They would somersault and the wife would dive on em' to hold em' down. Lot of fun, got emm' all. Thanks again.
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post #6 of 10 (permalink) Old 09-22-2010, 08:55 AM
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Quote:
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I pulled the lever off. The splines on the shift shaft are still good. The splines on the lever are shot. I used a lever from an ATC 200 for temporary use. It fits very nice and tight. I was able to use it to chase down some wild goats. The geometry isn't right but it "worked". I will get a new lever when I get to town. Thanks for the help. A "police manuavr" worked good on the goats at about 25mph. They would somersault and the wife would dive on em' to hold em' down. Lot of fun, got emm' all. Thanks again.
when you go to town to get a new shift lever..go to a hardware store, try to find a grade 5 or grade 8 metric bolt thats longer and the same threads as your shift lever..get a nut to go with it..then you can tighten it down from not only the shift lever threads..but when you put the nut on the bolt..it will never slip on the shaft threads again..not to mention..you won't have to worry about the bolt that goes in the lever breaking off in the shifting arm !.
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post #7 of 10 (permalink) Old 09-23-2010, 12:11 PM Thread Starter
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The Honda Shop wanted 79.00 for the lever. I ordered one from e-bay for 26.45 including shipping. I DID break off the bolt in the old one trying to tighten to where it would work. I WILL put a longer bolt and nut on the new one. The factory SHOULD have done that. Go figure. Thanks for the advise.
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post #8 of 10 (permalink) Old 09-23-2010, 01:27 PM
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The Honda Shop wanted 79.00 for the lever. I ordered one from e-bay for 26.45 including shipping. I DID break off the bolt in the old one trying to tighten to where it would work. I WILL put a longer bolt and nut on the new one. The factory SHOULD have done that. Go figure. Thanks for the advise.
Yeah, those bolts are soft and real easy to twist off. It's best to use a hammer and tap the hole together a little bit, on the shifter so it will fit tight. Then, tap the shifter on the shift shaft and put the bolt in. That way the bolt doesn't have to draw the shifter together as much and won't break so easy.

Most 4-wheeler problems are caused by a loose nut connecting the handlebars and the seat!!

You only need two tools in life -- WD-40 and duct tape. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape.
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post #9 of 10 (permalink) Old 10-21-2015, 11:35 AM
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Is it possible to "re-groove" the splines on the shift shaft instead of replacing it?
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post #10 of 10 (permalink) Old 10-21-2015, 12:06 PM
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yes, BUT to do so you would have to replace it and have a GOOD machine shop do so!

and the costs would be VERY high as to just replacing it!
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