This low use ATV came in with a hard shifting complaint. Also, the reverse lockout mechanism was not functioning correctly, where rider could shift into reverse under normal operation.
The RH side crankcase cover was removed to inspect the clutch. The clutch plates were found within specification and no signs of damage were apparent. The metal tab on the reverse lockout mechanism was bent, causing the symptom mentioned above.
While the crankcase cover was removed, the oil screen was removed and cleaned.
Here is the procedure to easily break the clutch plates free:
- With ATV running, shift from neutral to first gear and HOLD the gearshift lever in the UP position. This will engage the clutch.
- Apply front and rear brakes.
- Add throttle until engine breaks the clutch pack free. ATV should act if it were in neutral.
- Release gearshift lever.
- Take a short ride and verify hard shifting is eliminated.