[Mjp83]

I suspect I messed something up re-assembling the clutch side of the engine. Four wheeler shifts into all gears, but will not move forward nor backwards. Up on jacks it does rotate axles, but I can stop it easily.

Which clutch did I screw up?

How do I test to see if I put in one way bearing wrong?

 

[Mjp83]

Ok, after reading over some older posts here and there, it seems the problem is the clutch adjusting screw. I put a new front engine cover on this motor, as I am converting to 4 wd.
I had to install the adjustment screw into the cover and guest at its placement, I suspect I had it in too far, causing the clutch to completely compress, now it must be bound up, not releasing the springs to engage the disks.

Someone mentioned a trick to break the plate loose, holding the manual shift lever (12 mm wrench) for the ES model while revwing engine.

I will try this first.....

 

[Goober]

Someone mentioned a trick to break the plate loose, holding the manual shift lever (12 mm wrench) for the ES model while revwing engine.

I will try this first.....

I wouldn’t do that ... sounds like an awful idea ... give some time to get a few fresh responses on your question

 

[fishfiles]

I would think that if you had the secondary ( shift ) clutch apart , you pinched the plates when assembling , pull the cover back off , all the plates should be tight , none should be able to be moved with your finger nail

 

[Jeepwm69]

Check plates in the change clutch (see if they're floating in the basket, if so, loosen 4 bolts and wiggle hub around until you have tension on the plates/ the plates won't move) or you put the one way bearing in backwards on the centrifugal clutch.

 

[Mjp83]

Check plates in the change clutch (see if they're floating in the basket, if so, loosen 4 bolts and wiggle hub around until you have tension on the plates/ the plates won't move) or you put the one way bearing in backwards on the centrifugal clutch.

On the one way bearing: which way is is supposed to spin free and which way is it supposed to catch?

And can I pull the front cover off if I flip the machine on it’s rear, after I drain the coolant? I have seen people wash them like that but I was hoping not to have to drain the oil. (Fuel tank is already out due to top end repair).

Thanks!

 

[fishfiles]

Check plates in the change clutch (see if they're floating in the basket, if so, loosen 4 bolts and wiggle hub around until you have tension on the plates/ the plates won't move) or you put the one way bearing in backwards on the centrifugal clutch.[/QUOTE

If he finds loose disc , if I were him I would take the clutch apart and inspect the disc , I would bet the last one is bent ------- I beat on one that I bent with a hammer trying to straighten it out and I didn't use it , it was ruined

 

[Mjp83]

Ok, somehow during assembly I must have installed the clutch springs unevenly and caused the pressure plate to become lodged. Sure enough the disks were loose! Removed and re-assembled it and all is good.

BTW, drain the antifreeze, engine oil and remove fuel tank. Then remove fuel pump and lay on side. Standing up the wheeler was doable with my wife, as my winch had nothing to hook to in my garage ceiling....

 

[Mjp83]

4 wheeler on its back

 

[fishfiles]

...did you pull the disc out to check them for bends at the teeth when they got jammed ...

 

[Mjp83]

Did not separate the clutch nor pull disks, I removed springs, and wiggled the plate. Put springs on and paid attention to the disks and saw them tighten up. All together and drives and shifts like new!
Just goes to tell that one really needs to READ the manual during assembly!
Overall it was a great learning experience, and thank you all for the insights and the available repair manuals!