[J Mark]

Hello All,

Have been looking for answers here and in my manuals but can not find anything with my symptoms. All the knowledge here I am hoping someone can give me an idea to go from,

I have a ‘95 TRX400FW Honda Foreman. Used mainly for plowing snow in the winter. Have first and reverse but can not shift up. Happened maybe twice last winter plowing but it would work right after getting warmed up. The seal where the shifting shaft goes into the case had worked out after last season. Made a good puddle of oil on the floor. Just pushed the seal back in flush with the case and no more leaking. Changed oil and filter and now it will not shift up at all.

Clutch is adjusted perfect (according to the manuals and Shadetree's thread) and foot shifter works smooth in 1st and reverse. The rest of the machine all is running great. Never had any bad noises and has never been ran low on oil or hot.

Newer guy here so hope this thread is visible. My last couple posts said they had to be approved first.

Thanks,

 

[retro]

Newer guy here so hope this thread is visible. My last couple posts said they had to be approved first.

That seems to be a bug in our site software. I have asked the Admin to look into it so hopefully it will soon be fixed. Sorry for your inconvenience.

 

[shadetree]

are you sure the foot lever is not slipping on the shifting shaft ?, a lot of time the splines on the lever or the shaft will strip out !. pull the foot lever, inspect both the lever splines and shaft splines too see if they are stripped out ?, if they are ?, then you will need to replace both of them. the rear cover will need to come off in order to replace the shifting shaft, make sure you read up on this in the service manual !!!!!!.

 

[J Mark]

Shadetree that was one of my first thoughts also since I do a lot of forward / reverse when plowing. That would be one of the easier fixes I think. There is no play in the splines either up or down. First and reverse are still what I would call perfect shifting and smooth as is ever was.

After asking questions to repair shops am pretty sure it is a problem with the forks or rails now. Thinking that the front cover more than I want to tear apart myself but hate to pay big bucks to have it done also.

 

[shadetree]

yeah, pull the front cover, have a look at the lower front right ( when facing motor ), see how all the parts look on the front of the shifting drum ?.

 

[J Mark]

yeah, pull the front cover, have a look at the lower front right ( when facing motor ), see how all the parts look on the front of the shifting drum ?.

Thanks Shadetree. Looks like you seen my reply even if I can not see it nor did I know if it ever was sent. Not sure if it is my computer or this forum messing with me.

I will study the manual some more but thinking I will probably have a independent mechanic do the work for me. Found a local guy that does good work and reasonable finally. Just not sure I want to bring it in my wood shop and then get busy and have parts and pieces all over covered with sawdust.. Guess I need another shop to work on my toys. LOL

 

[retro]

It is the buggy forums code that is messing with you Festus. We see it from time to time whenever a username contains a period (.) or multiple periods. I have asked the Admin to look into it for ya. Hang in there...

 

[J Mark]

It is the buggy forums code that is messing with you Festus. We see it from time to time whenever a username contains a period (.) or multiple periods. I have asked the Admin to look into it for ya. Hang in there...

Retro I cannot see what I post so do not know if it sent or not until someone responds to it. Every time it says it will be approved by the admin. and disappears. I can not find any of my replies to your or any one else's posts. Just guessing by what you folks reply that you can see them at least.

I did send a PM to VS_Goose also and explained what was happening.

Thanks for working on this. I appreciate it a bunch. It is the first time I have ever had this happen on any forum. And no worries I am not going any where cuz I like this place.

Thanks Again, It is past my bed time. See you tomorrow.

 

[retro]

Yeah, we can see all of your posts so far... see ya tomorrow.

 

[J Mark]

Yeah, we can see all of your posts so far... see ya tomorrow.

So far this morning it looks like things are working good. Now I can get back to my shifting problem. Thanks for your help.

 

[shadetree]

chances are, the front of the shifting drum has issues ?, or..there is a problem with the clutches ?. nine out of ten times, there is hardly any trouble from a manual shift ?, and when it does happen ?, it's either the shifting drum ?, shifting forks ?, shifting star wheel at the front of shift drum ?, or return spring at the front ?. most of these issues are behind the front cover. if there is nothing wrong there ?, then the motor will have to be split to have a look at the internal parts ( just knowwwwww ya did not want to hear that huh ?!..lol ).

 

[J Mark]

chances are, the front of the shifting drum has issues ?, or..there is a problem with the clutches ?. nine out of ten times, there is hardly any trouble from a manual shift ?, and when it does happen ?, it's either the shifting drum ?, shifting forks ?, shifting star wheel at the front of shift drum ?, or return spring at the front ?. most of these issues are behind the front cover. if there is nothing wrong there ?, then the motor will have to be split to have a look at the internal parts ( just knowwwwww ya did not want to hear that huh ?!..lol ).

Hear what? lol No seriously that is what I am thinking also. Will be 3 weeks before I can get it in the shop. Should have started working on this problem this spring and would be ready to run by now. If I get time I may pull the front cover. Just hope it can be fixed before it snows very much which can happen anytime. Thanks for all your advice, it is appreciated.

 

[shadetree]

too save some time, lift the front of the atv up in the front as high as you can , this will keep you from having to drain the oil. if you don't do this ?, you will need to drain the oil before you pull front cover !. please also keep in mind, that front cover may have a gasket ? ( I have not looked ), if it does call for a gasket ?, have this on hand before you pull cover !. otherwise, you will be waiting around while it gets ordered. seems to me from memory..there is a gasket there. DO NOT USE RTV SEALANT FOR A GASKET WHERE A PAPER GASKET GOES !!!.

 

[J Mark]

I will check on that. Am thinking it is a gasket there.

 

[retro]

Yep, it has a gasket on the front cover:
https://www.partzilla.com/catalog/honda/atv/1995/trx400fw-a-fourtrax-forman/crankcase-cover-fr

 

[Apoe1989]

Hey y'all! I have a 2004 rancher manual shift that will not shift into reverse the back cable is connected and shifts fine into all other gears. Is it my transmission?

 

[retro]

Start a thread of your own with all relevant info Apoe1989
Else this one gets derailed... thanks.

 

[Apoe1989]

Sorry new to the forum thing

 

[J Mark]

Hello again All, Has been a few months of really busy in the shop making Christmas orders. Just finally got caught up and needed to update you folks.

So I was busy and decided to take my shifting problems to a independent ATV shop. Told him everything I knew including what Shadetree recommended. After having it for a month and nearing snow season I called to see how it was coming along. Said he pulled the front cover and there was nothing wrong in there. Put a new gasket on and back together. Nothing he could fix but cost me $175.00 to get it back.

A week later a friend was at the shop visiting and called his buddy asking about my shifting problems. His friend came over and asked if he could take it to his shop and at least see if there was anything he could fix. Sure I do not have time myself so go ahead. The next night he brought it back running and shifting as well as a brand new one. What did he do....? Exact same thing Shade said to do first only this guy was actually wanting to fix it. Just adjust the clutches and a bit of locktite on a bolt and back together. Less than 2 hrs. and done for no charge. Apparently my first in 10 yrs. oil change last spring just loosened the clutches a bit.

Have used it several times and it is perfect. A new buddy and machine and I am a happy guy. Thanks for great advice or I would probably had to take it to the local dealer who said it would be in the $1,200 range to fix. Like this place and good people.

 

[J Mark]

Here was the first play day this season.