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By 1FSTLS1
2006 Suzuki Eiger 400 4x4 runs fine has new tires. Garage kept just use it once a week to take the trash to the street. I got it about 8 years ago. I put a starter and battery in it about 2 years back. Has light bar and heated hand grips. I got a 6x6 and no longer have use for it. Zip is 25411/25422 WV.
Brad
304 six seven one - 179eight
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By PineAppleCawks
Morning all, hope everyone is off to a good start with their day.
about 2 months ago I bought a 95 bayou 300 for a hundred bucks. It was obvious the thing was gonna need some work and I'm up for the challenge. Just looking for some advice on how to get this thing going. The wheeler has an array of problems and I've done a good bit of reading around and learning about the machine lately, but I'm stuck at an impasse and not sure exactly what I need to do to proceed.
So to start with the stuff that was obvious to me; The wheeler has definitely been flipped, the handlebars and steering column are bent, both front and rear racks were bent and have been cut in places to allow the previous owner to bend them back into a rough idea of what they once were. Along with this the little box on the handlebars with the key and lights was completely missing, The ignition wires were hanging out the side and twisted together and the light wires were just freely hanging down below and were also cut, as they have no bullet connectors on them anymore. to deal with the loss of the reverse lockout they strung a cable through a hole in the plastic and attached a random handle to it.
As a preliminary I went ahead and purchased a info box complete with key and reverse lockout and a voltage regulator (as I had read they commonly go bad). I have a small question about the ignition wiring, but I will save this for later as this brings us to the actual problem. No matter how good I do at replacing parts such as this I will never know if any of it has worked because I cant get the transmission to shift at all, but most importantly I cant get it to shift into neutral. I did some research on the problem which consistently lead me to something having to do with the spur gear behind the secondary clutch. I pulled the clutch cover and inspected, Everything was in place with no loose bolts or anything. I went as far as to remove the spur gear and the levers and springs. I could not find any visual degradation that would lead me to believe this part is the issue. With time running thin in the day I went ahead and put everything back in according to the manual. for a brief moment I was very excited to find that the shift lever was actually giving me some sort of tactile feedback and felt as if it was shifting, but this was short lived and it all seemed to jam up and stop doing anything after a few seconds.
When I had the clutch cover off I had my son actuate the shift lever both up and down while I was laying on the ground looking at the spur gear. It seems that every once in a while it was able to grab the spur gear and spin it, but this will ONLY happen if im shifting up. It gets completely jammed trying to go down. Occasionally I can get it to spin partially as I am shifting down, but in those situations it freezes and wont spin any further even if I try to coax it along with a screw driver. What this feels like on the shift lever is there is no feedback. All I feel is the resistance of the spring and then it hits the a spot where it just stops the lever from moving. I get a very distinctive metal on metal "tink" and that's it.
Anyway this is my big hang up at the moment. If I cant get the wheeler in neutral I cant test to see if any of the electronics are working, let alone see if it will turn over for me. As a side note the pull starter is busted, when I pull it I just get the resistance of the spring and it doesn't seem to engage with the motor at all. When the clutch cover was off I grabbed the clutch and spun it clockwise which proved to me that the motor has compression and freely spins.
So that's where I am at now, and I am more or less out of ideas as to what I need to do to either further diagnose the transmission or (fingers crossed) fix it. I figure all the other stuff can wait, as this seems to be the big hinge point on the project at this moment.
I wont be at the farm till later, but when I am I will make a short video of the spur gear so you guys can see first hand what's going on.
I want to thank you guys in advance for any and all advice you may be able to give me. I am glad to have a resource such as this forum and look forward to hearing from you guys!
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By cmandsager
Do you recommend flushing and changing out the transmission oil in the 1996 Polaris Sportsman 500 I am trying to put back on the road? Not leaking and looks clean.
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By cmandsager
I am renovating a 1996 Polaris Sportsman 500. The owner lost the key, so I bought an aftermarket ignition switch. I noticed that this new key actually seemed to work in the old switch. Do you recommend replacing it or using the old switch?
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By cmandsager
I am renovating a 1996 Polaris Sportsman 500. It has not run for several years and stood outside in the owner's yard. There was some gas left in it which I need to drain. Do I need to drain the tank, fuel pump, and carburetor? Is there one place to drain it all?
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