400ex

mark40 · #1 (**permalink**) 02-05-2006, 01:00 AM

on a 2002 400ex i have a intermittent problem when the quad is stopped and i try to get it into 1st gear sometimes i have to really push down hard on the shifter to get it into 1st other times i have to get it rolling in 2nd then drop to 1st i tried adjusting the clutch this has made shifting better but still having some problems with 1st. my tech manual has me leaning towards the shifter forks and in order to get at this the whole thing needs to be disassembled im hoping to cure this externaly . AND PLEASE NO SHOULD HAVE BOUGHT A YAMAHA , SUZUKI , POLARIS , ECT. JUST REAL HELP THANKS !

superchicken · #2 (**permalink**) 02-05-2006, 01:19 AM

sounds like the clutch is dragging.Try changing oil,or check your clutch adjustment at the clutches.or you just may need new ones.

rpyfz450 · #3 (**permalink**) 02-05-2006, 02:09 AM

Should have bought a Honda! ...oh wait you did!

MudHole · #4 (**permalink**) 02-05-2006, 02:45 AM

<div class='quotetop'>QUOTE (rpyfz450 @ Feb 4 2006, 09:09 PM) <{POST_SNAPBACK}></div>

Quote:

Should have bought a Honda! ...oh wait you did![/b]

Now,Now,

He said he didn't want any of that.

MudHole · #5 (**permalink**) 02-05-2006, 03:03 AM

I would lean towards the fork also.

Your shifting into second rotates the the geardrum and frees up the forward fork so you can go into first and push the shifter down.

Its kind of like a syncronizer going in a manuel automobile trans. :twocents:

ridnwarrior · #6 (**permalink**) 02-05-2006, 05:30 AM

When the quad is not running...is the problem still the same?

Try this...with the quad turned off and in neutral.
Jack up the back of the quad.
While rotating the rear wheels in the forward direction, push down on the shifter.
Do not use the clutch while doing this.
If it drops easily into 1st gear, the problem lies with the clutch.
If it is hard to get into 1st, it is the shifting fork.
Let us know...

mark40 · #7 (**permalink**) 02-05-2006, 12:09 PM

THANKS FOR THE RESPONSE IM GOING TO TRY RIDIN WARRIOR'S TROUBLESHOOTING TIP THIS AFTERNOON THANKS .

mark40 · #8 (**permalink**) 02-05-2006, 08:42 PM

well i tried just what you said it went into 1st without clutch . i drained oil and removed right crankcase cover to reveal clutch , the lifter arm seems fine and works smooth no signs of wear, gearshift linkage rolls from 1st to neutral and back effortlessly . ( at this point clutch is disabled ) i did find that the lifter piece (as it is called in my honda manual ) was not able to move freely left to right or in and out freely i removed pressure plate and all discs and plates (keeping them in order ) all look good no discoloration or wear also measured springs and they are within spec. cleaned lifter piece and oiled it up along with the plates and discs re assembled clutch and now lifter piece is moving freely i'll have to wait to get a gasket for the cover to test it out i thought of using rtv sealant on cover any thoughts on this cause if it is ok to use i'll put it together tomorrow . alot of work just for a pesky 1st gear .

superchicken · #9 (**permalink**) 02-05-2006, 11:28 PM

I wouldnt use rtv,it WILL blow out.I know some times just dirty oil will foul the workings of the clutch up.

mark40 · #10 (**permalink**) 02-06-2006, 09:38 PM

yea i hear ya on the rtv . seems all they want is honda oil in there so i'll wait till they open on tuesday to get gasket , filter and oil . i do recall that my friend put some sort of oil additive in his ex once and after that the clutch always seemed to slip and only after 2 oil changes did it finally stop slipping . id rather wait and get the right stuff and do it properly . thanks for your help . mark
i'll follow up when it's all together again and let you guy's know how it is .