The pivot for the shifting linkage broke . So I took the left hand cover off replaced it put it back together , and it will now not shift . I took the right cover off checked everything . The clutch pack is new , the centrfugal clutch is new . All this was put in late 2008 . It ran perfect when the stud broke , shifted fine , and did not have a ton of hours on the bike . I have adjusted the clutch , have tried everything . Any help would be appreciated !!!!!
85 big red tranny issues
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Welcome to the forums. Is the clutch lever under the right side cover, in time? The clutch lever has a punch mark on it that lines up with an index mark on the crankcase. When you pull the shifter shaft out the left side, the clutch lever comes off the end of it and you have to remove the right side cover and retime it. This might not be your problem, but it's a possibility unless you already retimed it.
Yes I have lined the marks up . It is driving me nuts . I am pretty mechanically inclined , usually I can get anything going , this ond has me stumped . In another forum someone said shifting forks , but can't buy that , it shifted perfect before that stud broke .
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38,589 Posts
go back and remove the left hand side..closely inspect the shfiting arm..shifting wheel..return spring..all of it..something isn't put back together right.
So I took the cover off messed with the adjuster , got it to work . But now it won't shift again ???????? Guess it's time to shoot it !!! I don't get it I changed nothing in the shifting . I took the right cover off , the reverse shaft fell out I put it back in . Other than that I did nothing to it , any ideas ???
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23,587 Posts
Are you sure you have the triangular ball retainer and the other parts in the right way? That's the only thing that I can think of, sounds like those parts are binding when you put the case on.
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I remember having a problem getting my side cover on also but Helmut suggested laying the bike on it side so everything stays in line. Before I read that We did get it back on without laying it on its side but afterwards I was thinking DUH? that makes totally good sense! LOL
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23,587 Posts
You can also use a little grease to hold the parts in place, but I usually just turn the ATV on it's side and never have any problems.
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38,589 Posts
i found it very useful to apply some thick grease to that 3 balled plate..it holds it in place while i stick the cover back on..always works for me.
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38,589 Posts
just from learning all this shifting crap ( we won't go there ! )..that triangular ball thingy does not have anything to do with shifting the gears from 1st to 4th..it all starts in the shifting side..( left side )..if all that is working..then it will shift no matter what you have wrong on the right side..only thing that ball thing will do if it's not right..it will mess up the clutch part..but.seeing how he's trying to just get it to shift..and not running..it won't matter about that.
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23,587 Posts
Yeah, I know it usually don't, but if those parts are in a bind and that clutch lifter cam can't turn, the clutch lever on the end of the shifter shaft won't be able to turn either. The clutch lever has to be able to turn the clutch lifter cam under the ball retainer. I know it don't matter if the clutch disengages or not, but if those parts are in a bind, the shifter shaft won't be able to turn.
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38,589 Posts
now..i agree on that apart..when i was working on mine..i had the left side off..when i was shifting the gears..this was just to make sure it would shift..i never installed the right cover until i knew it would shift..lol.
Well last night it shifted all gears even forth but really hard , then it would not stay on gear in fourth , I would say after I took the cover off the right side something happened . No reverse which I had last night . And it clicks like 3 or for times between gears . Would the adjuster not being right cause it to do it ?? I am dumfounded I won't lie . It has to be in the adjuster . Only thing I can pin point it to !!
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Yeah, that's how I check them too. The clutch just won't disengage why you're checking them, but that doesn't matter since the engine won't be running. Sometimes you might have to turn the flywheel or output shaft to get the gear to engage.
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38,589 Posts
ok..lets get a clean start...first..remove the left side cover..pull the reverse lever out of the case cover if you pulled it out when you pull the cover off..now..first thing....shift down on the shifting lever..all the way until you can't shift anymore..in other words..find nuetral !..now..go to the right side..install the reverse lever as far into the engine case as you can..now..with a screw driver..or use your hand...( screw driver works because the spring can be hard sometimes )..pry the spring up into the case..carefully knock the reverse lever back into the case all the way..now..put the small washer on the reverse shaft ( hope you have it ..and didn't loose it ? )...now..line up the shifting arm to the index in the engine case..the arm has a punch mark on the end of it..the index you line it up on..is stamped into the engine case..looks like a arrow..slide the shifting arm on the shaft..now..put some grease on the clutch triangle thing..make sure you assemble this the right way..spring and all..the grease will hold it on there until you put the cover back on..also..on a side note..when removing the right side cover..do not pull the kick starter gear out..they suck at getting them back in if you haven't done a few !..lol. now..install the reverse lever arm with the 10mm short bolt..hook your reverse cable up..slide the cable into the reverse cable holder..tighten the cable nuts down..see how it shifts ?..if it still won't shift..then you problem is on the left side. also..don't forget your shifting arm and kick starter washers !
Ya that's what I am going to do go back to square one . Thanks so much for all the ideas !! I appreciate it alot . Both covers off , will get nuetral , then go from there , if the bike was not in such good shape it would be sold , lol !!!! Tired of messing with it !!
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we all have them days bro..hince..my signature ??..lol..it gets better..trust me..after it's all said and done..you get it fixed..you step back..and say to yourself..well crap..that wasn't all that bad to begin with !..been there sooo many times . just today..after a total top end rebuild on a '88 trx300....got it to run..but not for long..noticed when i kicked it..i wasn't getting any dash lights at all..well..i knew what the problem was...bad stator !!..after 3 stator changes later..i finally got dash lights on the kick..well..i thought..it's fixed to run...WRONG !!..now i wasn't getting spark..lol..i went over every damn part that was involved in the wire harness..i could not find one thing wrong..unplugged..nothing !!..sooo..today..when i got to the shop..i stood there looking at it..trying to think..now..it ran before i changed the stator..why did it stop ????..soooo..i thought..ok..it has to be in the left stator side..pulled the cover off..and as soon as i layed the stator down on the work bench..BAM !!..it stood out like a turd in a punch bowl..my fast paced working arse forgot to hook the pulse generator wire up to the pulse generator..lmao..sooo..no matter how mad we get..we learn from it..move on..and enjoy the ride !
Well after taking it apart numerous times , I got it working . There is a small pin on the end of the shifting drum that the shifting deal that looks like a gear lines up with . It would slip by it then back out the bolt that the shifting pawls are on . This making it not shift . I figured this out by looking at another engine I have laying here from a 250sx . I took it apart and I seen the pin was out farther . Long story short , it runs like a new one !!! Now I need to put fork seal in it , and the boots . Guess that's today's fun !! Then new tires and it will look almost like new . Thanks everyone for your help and ideas !!!! Todd
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