I have a 6 year old Taotao 125cc semi-auto ATV. Sometimes when you shift it's almost like it gets "in between" gears...like it's in neutral. You have to hit the shifter 2 or 3 more times to get it in the next gear. Also a couple of times while idling in neutral, it has suddenly popped into gear by itself. Is there an adjustment or is it time for a new clutch?

 

Sounds like either a bad shift fork on the end of the shift shaft... or a bad shift drum..

Adjusting the clutch cant hurt...there is a bolt and nut on the right side of the engine. could be under a cover.. loosen the nut.. screw the bolt in until it bottoms out and back it out 1/4 turn and tighten the nut..

 

I tried adjusting the clutch and now it doesn't shift at all. Ugh!

 

How many turns did the bolt turn in? or was it frozen?

 

It turned in 1 to 1 1/2 turns. Backed it off a little and got it back to shifting. Horribly but at least it shifts.

 

Have you ever changed the oil?

 

I change it every spring.

 

Id guess you have either bent or worn shifting forks.. it mounts to the end of the shift shaft and rotates the shift drum..You can see the forks by removing the clutch cover and the clutch assy..

 

I wouldn't be surprised if it is a bent shift fork. My boys aren't very easy on the shifter. The harder it got to shift, the harder they stomped the shifter. Which I guess could explain why it just kept getting worse. I'll check it out. Thanks for your help.

 

Ok I pulled the engine and removed the clutch cover today. The first thing I noticed was a burnt smell. The shift forks appear fine. Once I removed the clutch assembly and fly wheel I was able to shift easily through all gears. Time for a new clutch?