Ejwill

I’ll give it a try, Doc. didn’t do much to help pretty much said to keep on with physical therapy and the pain injections. Price is up there without insurance, we have Medicare and a supplemental insurance through wife’s retirement. So meet deductibles and it’s not too bad. Unless it’s something terrible happens. I’m going to check and see if each one is loose or all . I’ll start on it tomorrow my middle grandson has a football game tonight (American football). So have to ride one hour to see that probably in the rain. Hope to figure it out tomorrow. Thanks.

I checked the change clutch this morning before I left for the Dr. The plates are all very loose, I can move the all around wit my finger. They are really sloppy. Maybe this will help some, had to leave before really checking it out . I’m sitting in Dr. Exam room now waiting on him.

I’ll give it a shot . I was thinking if the threads are messed up on the change clutch shaft could it not being tightened up enough for the splines not to mesh up cause the shaft not to turn. I don’t have a whole nut on the shaft I realized it when watching to see if the shaft was turning. But looks like it would have to be up on the shaft spline to be that far on that the cover went on. Just grasping at straws. I’ll check what you said and see what I can find. Thanks. Might be a while before I can check it out. I’ll get to it as soon as I can.

Ok, change to my reply #170, I turned the centrifugal clutch and the change clutch outer basket turned but the shaft did not turn, the outer portion turned clockwise, but the shaft with the lock nut on it did not turn. Nor did the tires. Hope this isn’t totally confusing if so I’ll try again. Thanks again and again and again etc. So give me the bad news I’m used to it by now.

Glad you are here, join the crowd I had never done any mechanics on quads before . And I’m learning a lot now if I can get the transmission going so it’ll move it’ll be great, there’s some really good people on this site that are very knowledgeable and patient. I think you’ll like it here, stick around and try to pick up some of the knowledge that on here. Good luck with your quad.

Ok, I got the cover off and turned the centrifugal clutch counter clockwise and the change clutch turned clockwise. It was in gear at this time and the wheels did not turn as they were supposed to. I can move them forward by hand but not with the centrifugal clutch. Sorry I know you thought it may be something simple, but that’s not how it goes with me. Thanks for the help, if you know something else I can try I’ll do it.

So back the nut on the adjustment shaft out and screw the shaft in until it touches then back off 1/4 turn on the shaft then hold the shaft there and tighten the nut. I’ll try that and see what happens. Well, I did the adjustment like you said or as I understood. And the motor still will not turn the wheels. I shift up to first and can’t really turn the back tires forward by hand it’s real tight. They also won’t turn with the motor. I guess I’ll take the cover off like you said but not remove the lock nuts and clutches at this time. Will let you know when I get it off. Thursday will be spent at neuro surgeon’s. It’s about an hour and fifteen minutes from here. Hope to avoid surgery but got to have some relief. But I’ll get what I can done tomorrow morning by eleven or eleven thirty it’s about too hot to stay out there. I bought a battery powered ratchet which speeds things up a lot. Thanks again.

Ok, adjusted the clutch still nothing with the motor cranked the tires will still not turn under it’s own power. I know it’s going in gear I can feel it when it shifts and there’s a difference in the resistance when turning the tires by hand. I can shift up to fifth the higher the gear the easier the wheel turns by hand. But the motor will not turn the wheels under it’s own power. Thanks for giving me the correct adjustment for the clutch. Just don’t know. What turns the transmission inside the motor housing. When the motor cranks doesn’t the clutches turn, which turns the gears inside the housing - to the shaft to the differential. If so something has to be wrong with the clutch doesn’t it. I’m just guessing I have never worked on a motor before. Dropped a complete motor in a truck once but that wasn’t as involved as this. Thanks for the help.

I have not adjusted it, I’ll do that I don’t know if I read it or if one of you told me. I believe you turn the stud clockwise until resistance then back off a quarter turn. Not sure if that’s correct or not.

I have got things confused again. When I got everything together I cranked the machine and shifted into first and the motor did not turn the tires. I did not move. I jacked it back up and using the manual shifter and the electric shifter was able to turn the tires by hand. I could shift from neutral to first with the electric shifter alone as well as the manual shifter alone and back to neutral with each. I could shift to other gears with electric shifter by using the manual shifter to slightly back the shifter up until I felt a light click, then press the up shift button and it would go another gear. The tires turned by hand in each gear getting easier as I went up in the gears to fifth gear I could come down in the gears using the electric shifter doing the same. Could tell the gears were changing because the resistance was changing. For some reason it will not go under it’s own power I know it shifts into 1st because I can feel when using both electric and manual shifters. For some reason it just doesn’t move under its own power. Could it be in the starter clutch( centrifugal clutch) isn’t it the first one that picks up the motion from motor to wheels. I’m just guessing I don’t have a clue. Thanks Y’all for replying.

Ok, I’ll give it a try. Wish I could get it straightened out soon I go to a neuro surgeon on the tenth. So depending on what happens with him, Will determine if I can continue working on this thing for a while. If I have surgery maybe I can get one off my grandsons to do the work if I tell him what to do. That will probably never happen, they are too busy with school and sports. But there’s a change it may work out with them if there’s money involved. Thanks again.

I have the washers in right places, I have the gears on as shown in photo. The tires will turn when jacked up . They have resistance when in what is first gear is heavy as I shift up in gears it gets easier to rotate the tires. In fifth gear it turns fairly easily. The lower fears are pretty hard to turn I think this should be the way it should be. I think I confused you about the tires . I can turn them when it’s jacked up. But when I crank it up and put it in first the tires will not move under it’s own power, other words if it was on the ground it would not move. Sorry about the confusion,I didn’t explain it correctly. The gear cover went on easily. There was no binding there. I’ll check the voltage. I’ll check the voltage today. Ther should be 12 to 13 volts goin into the plug for the motor, right? If I unplug the connector for the motor and check the voltage across the two prongs I should get the voltage going to the motor? Electrical is way out of my league I’ll try but can’t promise you I know what I’m doing. Again the tires will rotate with lessening resistance as I shift up in the gears. The tire will not turn under it’s own power.

I think the gears are in place. The manual is confusing it shows the center gear turned upside down from the way I had to put it the big gear will not fit down inside the recessed area it has to go the opposite way. And the sector gear has to go under the center gear instead of on top as shown in the photo. This is a clymer manual page 181 photo 2A. Maybe this is the problem, but I can’t see how the center gear will fit the other way, and the shaft of the gear fit in the hole. I’ll take it apart again and make positive sure it will only fit one way. This could be a problem, I’ll see if I can straighten it out. I got the gears in as the manual shows, had it that way to start with. Still no tire rotation when I shift it in gear with the manual shifter. Don’t know, but what’s new about. Haven’t known much since we started but with y’all’s help I’ve picked up a lot I didn’t know, so thanks very much for the help. My middle grandson doesn’t want to go to college, so I told him to get a trade like welding, he could make good money, it’s just no easy work. I welded at a nuclear plant. It’s hot work. One area we had to wear ice vest to work in the room. And when you are dressed out and wearing a mask and welding hood , three pair of gloves it’s not very comfortable way to work. I feel like it's been that hot here working on this machine. Anyway I don’t know where to go next I’ll start with the trouble shooting pages I guess. Thanks again.

Yeah, it’s two bolts on the motor. I replaced the motor it’s new, I checked it with the battery before putting it in. And it worked fine. I’ll check the reduction gears, because they are hard to get installed with the cover on could be one of the has slipped out of place. I guess that could have happened not sure. I replaced the motor because the fiber board that has two small screws holding it in the bottom of the motor mount was broken at each screw. Can’t rebuild it so I just replaced the whole thing. It shouldn’t take too long to check the gears. I’ve been reading the manual and it calls for grease on the gears, I didn’t have any so I put oil on them, the grease might be what makes the difference. When I check the installation I’ll put the grease on the gears. Hopefully that might be an easy fix. Thanks again.

Reply to my own post. I worked with the shifting again this morning. I don’t know if I can even explain what it’s doing. As I said I put the bypass harness on it, and it will shift from neutral to first and back to neutral. If I use the manual shifter along with it I can shift up to fifth. I have to press the up button then take the manual shifter and back it up a little, I can feel a slight click. Then press the up button and it goes into the next gear I can do this all the way to what I think is fifth gear, then do it the same way back down to neutral. So far the tires will not move, it’s still jacked up so I can turn the tires if need be to make it shift to the next gear. The buttons work with help from the manual shifter, slightly backing the gear up just a little then it will go to next gear up or down again the tires still do not turn when it feels as though it is in gear.

I can’t see a thing on that dash it’s old weathered and impossible to see anything on. I tried cleaning it but it’s in too bad of shape. Didn’t what to put that much into it if the atv wasn’t going to work. I’ll try to do it again tomorrow, they sell new covers but I don’t see a way to remove the old one.

Oh well, guess you know what that means. I got everything on and it cranked right up, buuut it just sat there I shifted out of neutral to first and nothing. I even jacked it back up, cranked it up shifted to what I’m sure would be first and the tires did not move. I couldn’t shift in anything but first to neutral and back to first no other gears. I’m about ready to tap out. I know y’all are. I had ordered a harness that is supposed to bypass all the systems with the es system. When it didn’t work I put it on and it would shift from neutral to first with the buttons on the controls, but no further than first and back to neutral.

Well , I got it back together again. Everything is working so far still need to do a few things. Oil hoses, shift motor and gears, angle sensor,put gas tank back on, connect gas hose and hope it still cranks. It should haven’t changed anything with that. I took the front cover off to accesse everything easier. Will try to see if it works tomorrow. Got to put the left handle bar controller on bought a new one. Man I hope it works. Will let y’all know what happens. Thaknks for y’all’s help no matter what happens.

Ok, I loosened the change clutch lock nut and as you thought the tires would turn backward but really hard forward, you explained this earlier. I have taken the change clutch apart and checked the manual it says there’s one friction plate that has a wider diameter. It shows the difference between them as a wider friction pad area. The only different one I have had a smaller pad area and a larger opening that goes around the clutch center. So I’m a little confused about the difference in them. ‘A’ is the regular one, five of them. ‘B’ is the narrow one the only different one. But as you can see the pad area on B is smaller not larger as the manual shows. I guess I’m trying to see if ‘B’ is the one that goes on last even though it doesn’t look like the one in the manual. ‘C’ is showing the width difference in it and the other five. The second photo is from the clunker manual showing a wider pad area that it says should go on last . I don’t have one that is wider than the others just one that has a smaller pad area. I’m guessing the smaller with one in the photo of what I have goes on first, but I don’t have a wider on that would go on last. I went ahead and assembled the change clutch with the narrow pad one on first, if it’s wrong I’ll change it. Will put it on and not torque it but about 70 ft/lbs, as well as the centrifugal clutch. I’ll check to see if the wheels turn this time. I can always take it apart again.

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.