Honda ATV Forum banner

1 - 20 of 25 Posts

·
Registered
Joined
·
866 Posts
Discussion Starter · #1 ·
So i went to ride a little today, and when I went to shift into 2nd, the shift lever itself moved on the shaft, rather than moving the shaft.
After a closer look, i noticed the splines are rounded off in some parts on the lever, so I'm looking for a replacement.
Does anyone know where a good place to get one?
I've been looking for something aftermarket (since the new one, with rubber, will be over $40), but i cant find any made for atvs.
Are they universal for the most part? Like would one made for a honda dirtbike fit my 04 trx250?
 

·
Premium Member
Joined
·
23,581 Posts
I don't know where you would find an aftermarket shifter. One off of another Honda ATV or dirtbike should fit. Some of them may be a different length, depending on where the foot pegs are in relation to the engine, but for the most part, they should work. I don't know if all of them are the same size, but I think most of them are.
 

·
Registered
Joined
·
68 Posts
I am bypassing the broken push button shifter on the handle bars and am also looking to permanently mount a foot shifter lever. Permanently bypassing shouldnt cause any problems right?

The rancher came with a temporary foot shifter that you could attach on a temporary basis, but that is missing as well. It wasn't heavy duty material and wouldnt be a great candidate for a permanent fix anyway.

I have seen someone use a open ended ratchet handle as a foot shifter. That is probably not the correct term, but its basically a socket ratchet that has a square hole instead of the square nipple. The kicker to this method is that is has to have a certain diameter square. I cant recall if its metric or standard. Anyhow...I have seen that used. But like Reece, I would like to find a replacement shift lever instead of welding a ratchet handle onto it.

Any ideas would be great.
 

·
Premium Member
Joined
·
23,581 Posts
I am bypassing the broken push button shifter on the handle bars and am also looking to permanently mount a foot shifter lever. Permanently bypassing shouldnt cause any problems right?

The rancher came with a temporary foot shifter that you could attach on a temporary basis, but that is missing as well. It wasn't heavy duty material and wouldnt be a great candidate for a permanent fix anyway.

I have seen someone use a open ended ratchet handle as a foot shifter. That is probably not the correct term, but its basically a socket ratchet that has a square hole instead of the square nipple. The kicker to this method is that is has to have a certain diameter square. I cant recall if its metric or standard. Anyhow...I have seen that used. But like Reece, I would like to find a replacement shift lever instead of welding a ratchet handle onto it.

Any ideas would be great.
I've heard of people doing that, but I've never seen it. I read somewhere that you might be able to change that temp shifter shaft to the regular foot shift shaft. That way you could use a regular shifter. I think you have to take the shift motor off and remove a gear for it to work right. I read this somewhere, but I don't remember where.
 

·
Registered
Joined
·
866 Posts
Discussion Starter · #7 ·
I actually just ordered a folding shift lever on eBay, an IMS brand for "ATC TRX 200X 250X 300EX". I'm hoping that'll fit my quad haha.
Apparently the lever on it now isn't stock, since it's a folding style.
I'll be posting back with the results when it comes in.
 

·
Premium Member
Joined
·
23,581 Posts
I actually just ordered a folding shift lever on eBay, an IMS brand for "ATC TRX 200X 250X 300EX". I'm hoping that'll fit my quad haha.
Apparently the lever on it now isn't stock, since it's a folding style.
I'll be posting back with the results when it comes in.
It should fit. Yeah, you're right, I don't think the folding style came stock.
 

·
Registered
Joined
·
68 Posts
I dont see why you would need to modify the gears inside the motor. The temp foot shifter worked fine when I had it. My dad has also used the ratchet shifter solution. I will ask him what size he said it was. That may be alright. Its pretty sturdy if i remember right.
 

·
Premium Member
Joined
·
23,581 Posts
I dont see why you would need to modify the gears inside the motor. The temp foot shifter worked fine when I had it. My dad has also used the ratchet shifter solution. I will ask him what size he said it was. That may be alright. Its pretty sturdy if i remember right.
You may not have to. I'm just going by what I've read about it. I just remember reading that they said you have to take the shift motor off and remove a gear. I figured maybe that would make it easier to shift or something. I'm not sure, but I think that might have been on the High Lifter forums where I read that.
 

·
Registered
Joined
·
68 Posts
May have found a foot shifter, but I am not sure it will work.

It says its a XSL109 Honda Rancher Shift Lever that fits TRX350D Rancher 00-06. I wonder if this will for for the shifter nipple on ES models as well. Well regardless, it would be a great piece of medal to weld the socket onto. Website is:

http://www.atvworks.com/products.asp?cat=9

Anyone tried using this?
 

·
Premium Member
Joined
·
38,518 Posts
the shifting shaft that is for emergency shifting on elec models is about 14mm..17mm at the most..i do know it's metric...if it were me..i would find an old cheap socket...get a old shifter from any bike..this is to say..it's the right length !...cut the arm off the shifter..weld it to the socket that will go on the shifting shaft..after that..you may have to weld it on the shifting shaft that sticks out from the motor..just make sure you keep the motor shaft cool with water or your going to melt your shifting seal.
 

·
Premium Member
Joined
·
23,581 Posts
the shifting shaft that is for emergency shifting on elec models is about 14mm..17mm at the most..i do know it's metric...if it were me..i would find an old cheap socket...get a old shifter from any bike..this is to say..it's the right length !...cut the arm off the shifter..weld it to the socket that will go on the shifting shaft..after that..you may have to weld it on the shifting shaft that sticks out from the motor..just make sure you keep the motor shaft cool with water or your going to melt your shifting seal.
Yeah, that would work. Just keep the shaft cool as Shadetree stated. Just wet a shop rag or something and wrap around the shaft when welding to keep the shaft cool, so it don't melt the seal. Weld a little at a time and keep the rag wet.
 

·
Premium Member
Joined
·
38,518 Posts
will the replacement shifter on the website above not work for the ES model?
it said 00-06 trx350d..but it didn't say for the elec shift..they made two kinds..they made the trx350d manual shift..and the trx350d elec shift..and he's got the elec shift..and i think he's trying to convert the emergency shifting shaft to manual..and i don't think that shifter he seen will work...because the elec shift version uses a octagon shaped shaft..it's only for emergency shifting..it doesn't have splines like a reg shifting shaft does.
 

·
Premium Member
Joined
·
23,581 Posts
will the replacement shifter on the website above not work for the ES model?

The ES model just has a hex shape on the end of the shaft. It's just made for the temporary, emergency shifter, which has a hex shaped hole that fits over the shaft.

The shifter on the website you posted, has splines and is made for the foot shifted models. The shaft on the foot shift models is round and has splines on it that match the splines like on the shifter on the website you posted.
 

·
Registered
Joined
·
68 Posts
Ok. Gotcha. That is what I was wondering about. Im gonna go ahead and order it and see if I can tack it on the hex shaft somehow. That or weld it onto the metric socket.
 

·
Registered
Joined
·
866 Posts
Discussion Starter · #18 ·
I actually just ordered a folding shift lever on eBay, an IMS brand for "ATC TRX 200X 250X 300EX". I'm hoping that'll fit my quad haha.
Apparently the lever on it now isn't stock, since it's a folding style.
I'll be posting back with the results when it comes in.
So the lever came in the other day and I installed it today. I was concerned about fitment but it went on perfect. Fit like it was made for it. I haven't gotten a chance to ride with it yet but I'll repost if I find anything worth posting haha. If anyone is interested I can post the models listed on the package that it's meant to fit.
 

·
Registered
Joined
·
866 Posts
Discussion Starter · #19 ·
I tested out the new shift lever this morning at it's working great.
Just thought i'd let everyone know, in case you run into this kind of problem.
I had no luck finding a lever that specifically says it'll work with a 250ex tho.
 

·
Premium Member
Joined
·
23,581 Posts
I tested out the new shift lever this morning at it's working great.
Just thought i'd let everyone know, in case you run into this kind of problem.
I had no luck finding a lever that specifically says it'll work with a 250ex tho.
Glad the shifter worked for you.
 
1 - 20 of 25 Posts
Top