Honda ATV Forum banner

1 - 20 of 23 Posts

·
Registered
Joined
·
11 Posts
Discussion Starter · #1 ·
I have a quad that runs great, but I can't get it to shift consistantly. Any help would be appriciated...I'm pretty cluless on these trannies. Thanks in advance, Jason.
 

·
Premium Member
Joined
·
23,581 Posts
Are you timing the clutch lever? The punch mark on the clutch lever has to be lined up with the mark on the crankcase. Here is a picture.

 

·
Registered
Joined
·
11 Posts
Discussion Starter · #3 ·
yeah, it's lined up, but like I said, sometimes it works a little, then slips outta gear etc.
 

·
Premium Member
Joined
·
23,581 Posts
yeah, it's lined up, but like I said, sometimes it works a little, then slips outta gear etc.
Have you tried adjusting the clutch free play?

 

·
Registered
Joined
·
11 Posts
Discussion Starter · #5 ·
I did have it working the best, a couple of days ago , but it was weird. it would be in neutral w/ green light on. i'd shift down once, red light would go on but no movement shift down again and it would go in reverse. Then i'd shift up 1 nothing but w red light. up again, green light. up again, light would go off but no movement then up again and it would go up and down the gears fine!!!!!! what'n the?? hehehe That was the time I put it together with the end of the spring sticking out the bottom of the case causing the huge oil leak.
 

·
Registered
Joined
·
11 Posts
Discussion Starter · #7 ·
Any way, I thought i had it in useable form, I just had to tuck the end of the spring back in. I took it back apart and re-assembled it. now it's worse than [email protected] It won't even go into gear! This thing is becoming a vendetta, and I'm not gonna stop until it's fixed!!!! I really appriciate your time and knowledge!
 

·
Premium Member
Joined
·
23,581 Posts
Are you getting the rest of the parts in like in the diagram below?

 

·
Registered
Joined
·
11 Posts
Discussion Starter · #9 ·
what will the clutch adjusting screw control? it's so hard for me to explain!!! when I click up on the shift lever, it feels like it will go into gear, It just seems like it's not going quite far enough to drop into the groove, where it will stay engaged........sooooooooooo frustrating!!!! hehehe
 

·
Premium Member
Joined
·
23,581 Posts
what will the clutch adjusting screw control? it's so hard for me to explain!!! when I click up on the shift lever, it feels like it will go into gear, It just seems like it's not going quite far enough to drop into the groove, where it will stay engaged........sooooooooooo frustrating!!!! hehehe
The clutch adjusting screw adjusts the clutch free play. That's free play for engaging and disengaging the clutch.
 

·
Registered
Joined
·
11 Posts
Discussion Starter · #11 ·
NO!!!!! wait a minute!!! that's a great diagram!!!! I'm going to tear it apart and check that out!!! Maybe I'm not getting the lever in the right spot on the clutch lifter cam....
 

·
Registered
Joined
·
11 Posts
Discussion Starter · #12 ·
I'm going to tear into it again, in the meanwhile, if you have any other possible suggestions or steps, or diagrams, I'd really appriciate them. Thanks so much!!! I'll be back on later to give an update!!! Wish me luck!!!
 

·
Premium Member
Joined
·
23,581 Posts
what will the clutch adjusting screw control? it's so hard for me to explain!!! when I click up on the shift lever, it feels like it will go into gear, It just seems like it's not going quite far enough to drop into the groove, where it will stay engaged........sooooooooooo frustrating!!!! hehehe
That sounds more like the problem is either on the left side with the linkage or on the inside of the crankcase. Let's hope it's the linkage, because if it's not, then you will have to split the cases which is a bad job.

As long as it's not running, it should actually shift into every gear, even if you don't have all the pieces in the right side put back. I would check the linkage on the left side and see if it looks OK. Here is a picture.



There's a little roller on the bottom arm, in the picture, that fits in notches around the shift drum. That's what makes it stay in each gear. See if that's working right when you change gears.

Once you get everything in place on the left side, make sure you put the left side cover back on, because if you don't, when you put the clutch lever back on the right side, it will push the shift shaft back out the left side.
 

·
Premium Member
Joined
·
23,581 Posts
I'm going to tear into it again, in the meanwhile, if you have any other possible suggestions or steps, or diagrams, I'd really appriciate them. Thanks so much!!! I'll be back on later to give an update!!! Wish me luck!!!
Good luck, hope you get it.
 

·
Registered
Joined
·
11 Posts
Discussion Starter · #16 ·
What would happen if one were to put regular motor oil in the case(10w40) instead of stuff made for motorcycles?... just wondering......
 

·
Premium Member
Joined
·
23,581 Posts
What would happen if one were to put regular motor oil in the case(10w40) instead of stuff made for motorcycles?... just wondering......
If the oil isn't designed for wet clutches, your clutch will start slipping.
 

·
Registered
Joined
·
11 Posts
Discussion Starter · #18 ·
oh! That's good to know! I was raring to tear into that thing, but it started raining, and hasn't stopped yet. I'll keep ya posted!
 

·
Registered
Joined
·
11 Posts
Discussion Starter · #19 ·
Helmut, you said earlier that w/the engine off, I should manually be able to go thru all the gears, right? I s there a way to look and see if it is actually advancing thru the gears, or just staying in the same one?
 

·
Premium Member
Joined
·
23,581 Posts
Helmut, you said earlier that w/the engine off, I should manually be able to go thru all the gears, right? I s there a way to look and see if it is actually advancing thru the gears, or just staying in the same one?
With the left side cover off and the gear shifter bolted onto the shaft, you can shift through the gears and watch the shift drum. The arm has a roller on it that fits into the notches on the shift drum. Make sure you hold in on the shifter as you shift, so the shifter shaft doesn't pull out. The roller will go into a different notch for each gear. You will probably have to turn the output shaft or the flywheel to get it to go all the way into each gear. The arrow in the picture below points to where the roller is that locks into the notches. You should be able to feel it lock in and you should hear a click.

 
1 - 20 of 23 Posts
Top