Ejwill

I did check it it looks fine to me. Wish that had of been the problem. Thanks for your help

Welcome Charlesbrown, you’ll really like it here. Lots of great information on lots of topics.

Welcome to the forum there are some great people on here with lots of knowledge. I have a problem with all that wet deep snow too, here in southeast Georgia. Kidding haven’t seen snow here in about 15 years. Good luck with the utv.

What do you mean the OLD days. Jeeps and gamagoats were all we had. That wasn’t but what 50 years ago, wow I guess it was the old days. Time sure does fly. One minute you are track commander jumping off APCs the next minute you are 70 years old fat and disabled. Man🥲

Ok, I turned the star washer and got five full sprockets on it then I turned it back the same until it wouldn’t go further and turned the switch on and the neutral light was on. As far as the shift spindle and the manual shifter I think # 15 is still positioned on the shaft #9. I pushed the shift spindle back twisting it slightly, as it went. It has enough free play to twist it same as does the shaft #9. I eased the spindle back and twisting it I felt the part #15 because as I twisted the shaft #9 I felt it hit the #17 I could move the spindle when I twisted the manual shaft, so when I bumped them together I eased them apart pulling the spindle back just a hair twisted the spindle so that # 15 would turn down just a little and pushed them together I felt them hit and after that I could move the spindle back and forth with the free play that is in it with the manual shifter. They may be connected but I of course can’t be sure. And if the spindle moves out the connection will come undone again. Hope this is what you meant to do if not I’ll try again. Not pertaining to this I hit the hand brake and the brake lights came on. Will work on other electrical issues after this is solved (I hope it gets solved). Thanks again for your help and you too, GW. Looks like I may have spent more on tools than parts at least I hope that’s the way it works out. I can always use more tools. Thanks again.

Well, I hope this is good news for a change. I got the star washer turning with the roller in place. I pulled out on the shaft and turned it a little as you said and I could tell it connected up I turned the star washer still having to sometimes move the shaft to get the star to go all the way dow in one of the slots, but it did turn I turned it as far as I could get it to turn one way and turned the ignition switch on and the neutral light turned on. So I guess it’s in neutral now. I haven’t tried the manual shifter since it hasn’t been working I figured it still wasn’t. I’m pretty sure the star washer had the roller move in five slots. What do I need to do next? Haven’t really done anything to fix a problem just tore everything down. Thanks for getting me this far. I think when and if this thing is ready to reassembly I’m going to change out the friction plates and metal plates and springs while it’s apart. They don’t cost that much.

I can’t get the star washer to move but one notch now. Haven’t changed a thing, except try to get it to turn with the roller in place it would move one notch like that also. None of the parts connect to the star washer move when I try to shift manually. The tires still roll freely and turn the crank shaft but I can’t turn the tires by turning the crank shaft, I could earlier. Don’t know if something changed when I was trying to turn the star washer while it was engaged with the shift arm. I tried turning the tires with the shaft an the shaft just rotated round no resistance. It slides in and out and I feel it bumping on both in and out. Don’t seem right the tires turn it still but it won’t turn the tires. I have no clue. Sorry for getting y’all into this mess. I’m probably not explaining everything so you know what I’m talking about and that makes it harder on you. Think I’ll just take the motor out of my wife’s Rav 4 and put it in here.😂

When I tried to shift with the manual shifter the shift cam/ star washer does not move at all or even try to move. Or the change arm/spring loaded arm with the roller neither of them move.

The manual shifter and the gear spindle are not connected in the back .I could move the spindle and feel it bumping the manual shaft. I kept twisting them until the coauthor on each other. I could move the manual shifter free play and it would move the spindle about the same. Pretty sure I just got them hung up to do that, not connected . It looks like I need to pull the engine and go into the back cover. Seems like it is possibly more than the spindle and manual shifter not being connected by the linkage. Don’t know what but it’s locked up so tight seems like it must be in the transmission gears. I’m just guessing y’all are the pros, what do you think? Thanks again for all the help, I know this has been a long post and I appreciate y’all hanging with me on this. It’s some experience. I’ve measured everything in the clutches by the manual and everything looks good. Showing some wear but nothing serious. Digital indicator came up within specs. Of course you can always have a little human error. But everything I think will work ok. One shaft bushing was out .04 but I just feel someone else would have gotten something else if they measured it. Everyone has a little different touch. It wasn’t scratched or gouged. So I’m letting it go. It’s not a nuclear plant. But I do want it right. Thanks again for the help and advice.

I got the clutches off the change clutch came off without any force. Just came off by hand. Don’t know if that’s normal or not. The star washer turned by hand while holding the arm off of it . But the tires still turn both ways freely when I thought they would be in gear, and the manual shift will not shift. It has about one half inch of free play in it turn that much before it stops solid. I’m pretty much lost from here. Found nothing broke or badly worn. But all of that seems to be out of play now. When the tires turn the shaft turns but not the what I think is the sub shaft does not. I was afraid it could be the linkage on the back of the spindle, which you can’t get to from the front. But I don’t know anything else to do. Thanks for any help and direction from here. I think It may be getting deep from here on out.

I got the centrifugal clutch off and the change clutch. I was wondering though, the change clutch came off with the centrifugal clutch, didn’t have to use any kind of puller. It just slipped off. Could something be wrong there? I worked back to the shift cam/star washer and held the stopper arm away from the shift cam and it turned pretty easily by hand. I turned it counter clockwise until it stopped then back clockwise about five sprockets. I thought maybe when it stopped turning counterclockwise it may have been in neutral but when I turned it back clockwise the tires still turned freely. The manual shifter still will not shift, and it has about a 1/2 inch of free play in it. I have no idea from here.

GW, I tried to take the nut off as left hand threads but wouldn’t budge. So I locked the gears with the aluminum tent peg and turned as standard right hand threads and it came right off. Just wanted to let anyone reading this so they would know what I had to do.

I haven’t yet my meter crapped out on me and had to get a new one. I get most of my stuff from Lowes because I get a veterans discount. But they’ve got wher the don’t keep anything in stock you have to wait till they get it in. Anyway, I’ll check it after I try these nuts a little while longer. Thank for the help. I’m getting to the point I hate to walk out the door and see the thing. I’ll keep on keeping on for a while longer.

I got the 27 mm socket today and the centrifugal clutch nut will not turn . Mech you were right about the soft metal in the gears it holds it tight. I ended up using an old aluminum tent peg works great, sure beats $179. Now if I can get it to break loose. It looks like I got all the stake off. Someone else has been in this atv the stakes looked like someone had messed with them and on some of the connectors someone had marked three of the wires going into it. I’ve never had it worked on before Maybe my son did after the grandkids got through with it. The screws were out of the handle bar controls my youngest said they must have fallen out, I don’t think so. No telling what’s been done to it. Going to take a little more off the nut at the threads to see if it will come off. The impact wrench is 24V and supposed to have 400 ft/lbs of torque but I don’t think it does. Thanks for sticking with me this long . I know this is getting to be a very long post, but maybe it will help someone else too.

I don’t know. I had 12.2 V at the ignition switch and 12.2V at the starter switch and the light switch. I’m thinking it might be some of the connector they go through for the others wires. I checked continuity on the red wire to the first connector and it was good, not sure what the black wire from the ignition switch is but it may have a problem I’ll recheck it today. Electrical problems are a pain in the rear. I’m not sure how to check the wiring that runs from front all the way to the fuse box, but looks like to me if I’m getting the 12.2V to the switches they should have worked. Got to figure on how to check the tail lights.that socket for the clutches won’t be here until Monday they say. So I’ll keep fumbling trhojythis electrical stuff.makes it had on someone who’s color blind, that why I eent into mechanical maintenance instead of electrical.

Thanks a lot I’ll check it ou tomorrow Thanks for the help. I’ll Let you know what I find.

Yes starter works. I had it running before the gear shift problem came up. Just couldn’t shift gears. Thanks for all your help it really means a lot, to have someone help like that.

No I’ve been trying to deal with this gear shift problem, so far I’m spending and waiting on tools more than parts. Getting a battery impact wrench and a 27 mm impact socket to remove the clutches . I found another video on the trx350te engine tear down and it said the lock nuts on both clutches were 27 mm. Hope they are right. Should be here soon. Figured if it didn’t run I didn’t need the lights. So I put them on hold for now. But hopefully I’ll need help on them before too long.

I got the bearing off no problem, I checked the lock nut on the centrifugal clutch and change clutch. Only size socket I had close to a 20 mm was a 21 mm it was to small for the change and centrifugal clutch lock nuts. The repair manual I have doesn’t give the size of the lock nuts on the clutches. I tried to measure in inches and it came up to equivalent of 30.14 mm so I not sure now what to go with. I don’t have sockets that large in mm to try. I’m going to measure again to get them closest socket in inches and try that. Will post the size I can get to work incase someone else is trying this.

Thanks I would never got it off , would have been turning it wrong way with a four foot cheater bar wondering why it wouldn’t come off.

Thanks I will try locking the gears. I have some aluminum strips I can try.

I was going to take the centrifugal clutch off and got down and found a bearing stuck in front of the nut. Evidently the bearing had come out of the cover. Now I’ve got to pull that bearing off to get to the lock nut. Which by the way do you know the size of the nut on this clutch is and the one on the change clutch. It would be good if the manual said what they were they are hard to get to to measure and guess at. It said to use a special tool on this one and the change clutch, I checked and at least one of them sells for $179. I’d like to get around spending that much on a tool I’ll probably use only once. Thanks for your help. This is getting worse and worse. I guess if that bearing doesn’t fit tightly in the cover I’ll have to get new cover.

Crap, I think I’m getting too deep for my skill level. Might just need to take it out to my son’s house and see if I can just set it. I’ll take a gallon of gas with me and set it —- ON FIRE!!! Getting to be pretty complicated. Should have taken it to someone capable of fixing it.But they would have charged me an arm and a leg, but that’s out because I only have one leg now so they want be getting the other one.🤣

Yes I’m going to get the motor. I’d like to get the shifting problem resolved with the manual shifter, before I put too much more money in it. But that’s in another post. Thanks for your help.

Thanks for the reply. I’ve seen the motors but they are useless without the brushes inside the body the shift motor mounts in, it is the brushes and wires in the bottom is a fiber board base that is held in by two screws this board is broken making this part that holds the brushes useless. Don’t know if I have to buy a new housing or if they make a kit to repair it with. They have brush repair kits for starter motors, but I can’t find one for the gear shift motor. I may just try to rig it with washers that will cover the breakage and see if that holds. Maybe add a little glue first.then I will straight wire the motor to the battery and see if it works. Will post the results.