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2004 Suzuki Quad Sport stuck in gear

wylee04

By wylee04
in Suzuki ATV Forum

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DirtDemon

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The first thing I would do is check all the external shift linkage, since it is easier. There is a small shaft between the gear shift lever and the gear shift shaft, an adjustment there may solve your problem. It sounds like the shift ratchet is working, but maybe it isn't turning the shift drum. If you listen closely, you can hear the gears actually changing inside the gearbox. I would give a listen while you are trying to shift through the gears and try to determine whether you are just hearing and feeling the shift ratchet clicking, or if there are gears moving inside the tranny. There will be more noise and resistance if gears are actually being switched. If just the ratchet is working, the shifter will move more easily than usual, and you will only hear the click of the shift ratchet. If you think only the ratchet is moving, you may need to pop the side cover off of the motor on the right hand side of the machine, this is the cover on the side opposite the gear shift lever. Between the shift ratchet and gearshift drum, there should be a small pin that the shift ratchet uses to turn the drum, this may be broken.

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