Ejwill

Yes, when I thought I was ready to assemble it. Everything is on the change clutch the sleeve / bushing, the housing and big washer, the plate and the friction plates and metal plates washer x2 then nut. I’m sure all of that is in there. Oh and the seat and cupped spring around the clutch center.

It is really hard to turn the change clutch even in neutral. If I put a ratchet and socket on it (the nut), I can turn it but that’s the only way. The sub gear spindle keeps coming undone from the manual shifter shaft I have to put pressure on the manual shifter handle to make them stay mated up. I don’t have any help so I have to tie it so there’s pressure on it if I attempt putting the cover on and off. I think it may be hitting the change clutch sides when I try to put it on but not sure. Still it is so hard to turn without the cover on. Don’t understand what has changed. I have the sub gear spindle put together right now as it will shift up to fifth and back to neutral. But something just doesn’t seem quite right to me but what do I know. Just doesn’t seem right for the tires to be locked up like they are. Thanks for getting back to me on this I know you are about as tired of it as I am.

True, True I’ve got the clutches on and torqued. The nut on the change clutch was too deep for the socket to get a grip. So I added another washer, that worked as far as torquing it but don’t know if that changed anything. I’m having trouble getting the cover to go on jam up to the housing . It will go up to the dowels, but that leaves a gap between the cover and the housing. Didn’t know if adding the washer made a difference or not. If I go to any gear I can’t turn the tires at all. I feel like they should turn backwards at least. But don’t know still feels like it’s shifting with the manual shifter. Just seems like the tires are locked up. Hope don’t need to pull the clutches again but if I do, I do.

Ok, my mistake, sorry when I took the clutches off I took everything off to clean all up. Should have done it in the first place. When I put it back together except for the clutches I put everything on the sub gear except the ‘#%!!!** arm’ that goes behind the plate and spring . I knew something didn’t look right so I checked where I kept my parts and saw it, put it on and tried the manual shifter and it went through all 5 of the gears and back to neutral, had to roll the tires but it did shift to all the gears. I guess I can put it back together now and hope for the best. Waiting for weather and me to cool off a little. Hate this hot weather. Would like to move to Alaska, I can handle the cold better. You can always put on more clothes but you can only take off so much without getting locked up. Anyway I’ll start putting it back together later this afternoon unless y’all can think of something else I need to do first. Thanks for the replies.

Ok I’ll give it another try. Thanks.

That’s it , nothing that I know of everything is the same except the clutches are off and it shifted ok before with them off that’s why I went ahead with the assembly. The manual shifter feels solid like it can’t move. It still has the play in it that moves the gear spindle a little, which I think that’s all it’s supposed to move. I have no idea. What gets me is the star sprocket when I move it it doesn’t seem to affect the tire rotation. They still turn freely like in neutral.

I got the nut on and the threads look ok. I use a dermal with a small cutting wheel and took off the bad threads at the beginning of the shaft, I got it started by hand and ran it up with a ratchet. So I think I can make it work. I took both clutches off to check the threads on both the change clutch threads were a little messed up at the beginning but I was able to fix them too,. The only problem I’m having now is it won’t shift with the manual shifter again. The manual shifter hub is still moving the sub gear spindle so they must still be connected. I turned the tires and no shifting. I was able to get to the star shifter and move it a couple of sprockets but the tires didn’t feel like it was in the low gears. They turned like they were still in neutral. But the indicator light , green light was not lit. So I don’t know if there’s any need to continue putting it together now or not. Thanks for y’all’s replies.

Actually it’s severe arthritis, spurs and 2 buldged disc. Makes it hard to do anything on the atv. But I’m not giving up got the nut off waiting on some more parts should be here by the 29th. Hope then to get everything back together again. This time for good, I hope. The threads on the shaft don’t look too bad. The lock nut was staked into the threads so they were messed up when I had to grind the nut off. But I think I can fix that. It would be great if I had a nut die that would fit it, but I’d probably never find one. I’m just going to try to work it out and see what happens. Thanks for hanging in there, maybe when I get the parts I’ll be able to wrap this up. If it works, if not guess I’ll have to go further.

Thanks everyone, it’ll be at least tomorrow before I can do anything. This neck has got to be fixed. Makes it hard to do anything. I’m going to get the nut off and fix the threads used to do it in coal fired plants, not allowed in nukes. Don’t know what happened I put oil on the nut and did have a washer on the shaft with the nut. As I said earlier someone has been working on this atv, the lock nuts were staked into the threads. I cleaned them up and the nut went on by hand with no problem. It was the same on change clutch except where they tried to stake the nut the nut went into the thread space but it looked like the thread area broke off. No idea who could have worked on it my son said he didn’t have it worked on and I haven’t, unless of course the dementia is kicking in but I don’t think so.Thanks again for the replies. Hopefully I’ll get something done on it tomorrow.

I tried a flat tip screw driver and couldn’t get it back there. I’ll try again tomorrow. Had to give it up for tonight to work on a lamp for the wife, practically rebuilding the lamp. If that shaft is messed up too bad when and if I get the nut off. I guess I know what that means, splitting the engine to replace the shaft. Sure was hoping to avoid that. May just get a few bucks out of it for parts. Depends on what the Docs. Say about my neck tomorrow got to have an epidural, can’t hardly turn my head to the right. But that’s the way the mop flops. Thanks for your replies. Won’t have much time in the morning to do anything.

Thanks for the reply kp3004x4. Well, I have really run into a problem. I decided to check the torque on the centrifugal clutch to make sure it was all the way seated. I put the torque wrench on it and tried the lock nut and it moved without clicking so I kept on and it wouldn’t tighten. I don’t know why it set the first time. I put it on the shaft and ran it almost all the way down the threads by hand to start with. Now this, it’s like the nut is stripped or the shaft is one. It won’t come off or tighten up. I have a dremmel I may try to cut the nut off can get it to go either way, don’t know anything else to do. Man thought I was getting close to rapping this thing up. But my usual luck kicked in. Sorry about this I know y’all were ready for me to get through too. I have no idea what has happened. It’ll come approximately three threads from the end and won’t go any further.

I understand more now thanks. I was checking the cover in the manual it says it will just slide into place, it goes easily up to the dowels, but there’s a bearing that has to go on the centrifugal clutch shaft it is not just going to slide on the shaft without resistance. If I get it to the dowels should I go ahead and pull it down? Or is there something wrong? Thanks again.

Welcome a great place here, I’ve learned a lot. I have a Honda 350 rancher es. Clutch problem we hope don’t want to have to split the engine . There’s some good people here and someone is willing to help if you have a problem. Welcome again and hope you stick around.

I’ll have to check them out. Well I got the clutches on and torqued down. I thought I would before putting the cover on and adding oil. I would check the shifting . It’s in neutral the tires rotated easily both directions. It shifted to first the tires could hardly be moved they would move with some force backwards they would not move forward at all. Same for second, when I got to fourth the tires rotated easier backwards and had to be fought to move forward, fifth gear it moved fairly easy backwards but I barely got it to move forward. Is this as it should be or is there something wrong?

That’s a good idea, where did you get magnetic bowls? I also saw on a video a guy used zip ties to put through the parts like washers and clutch parts as they came off the shaft so you could keep them on order. Thanks for all your help through all this time.

It is habit forming my wife keeps telling me I need to come in out of the heat, but if I do all I do is sit down here thinking about what I need to be doing on it. I don’t know if anyone is following this because they may have to do the same thing , I’m no mechanic but one thing I can tell them is when you take something apart bag it or something and label it so you have all the parts for that one item all together and not all mixed up. I looked on eBay for the lock nuts about all they had was pre-owned, I had pre-owned ones didn’t want to by someone else’s. Hope to get this thing done as soon as they get here. Thanks for sticking around and helping, been a long post. Don’t know what the record is.

Everything is good. I have to get the parts here, the lock nuts. I got them ordered, not changing out anything as far as the clutches. I’ll get what I can done while I’m waiting on them. Thanks, now if I can put it back together right. Hope it will work I know y’all will. Mech, y’all- southern slang.

Ok Mech, I tried the gears again, I put pressure on the change clutch shaft. Pulling out on it. I turned the shaft by hand pulling on it a little as I turned it. I got what felt like five gears with the shaft turning. I could hear the star washer and the arm turning to different sprockets. I went up to fifth and back to neutral. Did it several times. Sometimes it felt like it stopped on the tip of the gear but with the shaft turning it dropped to the bottom of the sprocket. Do you think I should start putting it back together again? And what changed by just taking it apart. Not doing anything but take it down? Just wondering what fixed it. At least I hope fixed it. Want know for sure until I crank it up and try it. By the way I’m having a mare today. Was said to be slang in N.Z. For having a bad day but I guess I blew that one.🙄

Ok, I’ll try that while waiting on parts should have already ordered them but waited till the last minute. Usually get here pretty fast. Thanks

Yeah , hope I didn’t break the driveway. I think you were right about the nuts on the clutches. I was talking about the socket size and I think you had the bolt or shaft size. The wet clutch is 20mm and the change clutch is 18mm. I don’t understand why they have the same socket size. But they were both were 27mm socket. I didn’t make myself clear about that. At x-ray now. I’ve got to order parts before I can do more . Lock nuts and I’m putting a new handle bar control on it since the screws had been removed. I’m sure it had gotten water in it at some point it didn’t look too good on inside. What’s a good way to clean connectors. A lot of them look like the have so kind of corrosion on them. Thanks for your help and concern.

I had written all this and was about to submit it and my daughter-in-law called to check on me and I lost it all. I got to the interlock and could push it with my thumb. It felt like it only moved about 1/8 or little more and sprung back, it felt more like a switch than anything. I went ahead and put the cable back on it there’s a lot of slack in it right now . I went ahead and put the plate #9 the spring #8 and the arm #7 on the sub-gear spindle and tried the manual shifter. I’m getting three gears out of it and back down to neutral. But that’s all I can get. I think I’ve put about a mile on this thing spinning the tires. But couldn’t shift any more than three. Which is better than it was. Would adding the change clutch make any difference at this time? Just wondering I have no Idea. Thanks for getting me this far. Maybe it’ll all come together somehow.

Ok, I’ve had the wheels jacked up using them to turn the shaft. I located the reverse interlock and got the cable off. I may never get it back on but it’s off for now. I had to go to a friend’s house today and was loading my power chair on the carrier on the back of my car and it flipped with me and I hit my head on the concrete. Didn’t knock me out but almost. Haven’t got hit that hard since I boxed in the military. I’m feeling ok right now so I’m going to look for some movement in that reverse interlock. I’ll let you know what I find. It’s not in the best of places to get to but appears to be better from the right side of the atv as you would be sitting on it. I’m heading out there now. Thanks again.

Yeah, I looked for it earlier. Traced it from the handle bar to rear of the engine it’s on the back and under the engine a little. I’ll take a look at it a little later when it cools off some our thermometer here at the house had 102F just a little while ago. I’ll get tonight or first thing tomorrow. Probably tonight I can’t put it off or I’ll be thinking about it all night. The shaft you were talking about turning was the change clutch shaft right or was I wrong . Just let me know. Thanks again for the help.

Ok, the sub-gear shaft the one the angle sensor goes on only turns a little just some free play the same amount of free play the manual shaft has. They don’t feel as if they are connected to anything else but each other. Neither of them reacts with the star washer or roller arm is moved. The sub-gear spindle is still locked up except for a little free play as well as free play in the manual shifter. That’s all they move.

I know GW I really appreciate all your help. This has been a long journey and not there yet. I still don’t know what I have to do to fix the problem. I hope it isn’t too far off from being fixed . I really haven’t done anything to fix the shift problem, just did some things that provided some information that may get me there. Good to hear from you, thanks for your help. I understand that you have things to do and you have other people to help. I do appreciate your help with my problem. You, Mech, and Ozark have been a help and thanks to you all.