I have alot of play in the shifter. So much that the shifter hits the floorboard and won't put the transmission in gear.

Is there an adjustment on the 2000 500 model that I'm missing to take up some of the play in the shifter?

Also, does anyone have a link to a service manual that I can download or read online?

Thanks in advance for any help.

 

check to see if the bolt came loose off the shaft, or the splines might be stripped

 

Esko

On the right hand side of the transmission case nearest your right foot should be either a small circular plug with three bolts around it or an oval shaped plug with 2 bolts holding it in place. It is usually near the oil fill plug.

If you remove it, depending on which type it is, the jam nuts for adjusting the clutch on the manual transmission are under it. The specific instructions are in the service manual. If you find the plug and do not have a manual, let me know and I will send you the instructions from my service manual.

You should also check to make sure the shifter has not loosened up. I do not think that is the case because the bolt that tightens the shifter onto the geared shaft goes through a small keyway that would keep the shifter from slipping. (unless something is really messed up on the keyed shaft there which you would notice)

I usually check my clutch adjustment on my 400 manual when I change my oil.

Oh, welcome to the forum.

SJ

 

Thanks SJ, I will check for that adjustment on the right hand side. The shifter is not loose. The splines are fine. I have enough grey matter between the ears to check for things like that (i think).

It would be great if you could send me the service manual instructions. Looks like I need to go out and buy one since it's geting old and probably going to start needing more and more TLC in the future.

Thanks for the welcome. Looks like alot of great peolple and good information here.

 

Esko,

Here are the 6 steps for clutch the adjustment. These are from a service manual for 2002-2004 machines but, since you have a 2000 AC500 it should be fine. There were not that many huge changes between 2000 and 2002 except for carboration if my memory is correct. Here goes:

Locate the small oval cover on the right side of the tranny by your right foot.

1) Remove the screws securing the cover and remove the cover. Account for the O-ring (which can stick to the tranny case or the cover).

You should see 2 jam nuts with a slot in the end of the bolt. There may be a little residual oil here as well that you can wipe away with a rag.

2) Loosen both jam nuts. The (forward most) adjustment screw is screw #1 the (rearward) adjustment screw is screw #2.

3) Rotate adjustment screw #1 COUNTER-CLOCKWISE until it stops.

4) Rotate adjustment screw #2 alternately CLOCKWISE and COUNTER-CLOCKWISE to ensure free movement without binding; then lock the jam nut securing adjustment screw#2.

5) Rotate adjustment screw #1 clockwise 1/8 a turn and lock the jam nut securing screw #1.

(I find it easiest to keep a screw driver in the screw slot and then tighten the jam nut with a wrench, 10mm I think, to keep the screw from moving)

At his point the clutch should be adjusted properly. Take it for a quick test spin to make sure. If it not adjusted correctly repeat the steps #2-5.

AND you may hear or feel a click when you turn the screw in step 5. From what I have learned and experienced this is OK. If you repeat the steps a couple of times you are advancing the adjustment 1/8 a turn each time. Theoretically of course.

6) Install the cover making sure the O-ring is properly in place and secure with screws. It does not give torque specs for them. I also put a small oil film on the O-ring if there is not one already before installing it.


That's all there is to do. Not too difficult and takes about 15 minutes maybe a little longer if you have not done it before. As I said before I check this with every oil change which is about 2-3 times a year. You may have difficulty finding a service manual for your machine that is 7 years old though. It's not impossible just difficult. That is why I would suggest getting a service manual with the machine when it is new.

Hope that helps Esko.

SJ

 

SJ, Thank you so much. I will do this either tonight or sometime this weekend and let you know how it turned out.

Next new one I buy will have a service manual following it shortly.

Again, thanks. Have a great weekend.

 

Thanks for the info swampy, I have the 02 400i manual and have 600 miles on it, and never knew there was anything for the adjustment, never had any problems either, maybe thats why lol, But do you or should you check it every oil change?

 

Hello all ,

Will the adjustment work for a sticky or somewhat hard shifter ? I have an 01 400 manual and it is a bit hard and sticks sometimes ...

 

I check mine about every oil change. I have been putting approximately 1500 miles a year on my machine and the service manual says to check it at the 100 miles mark, then every 500 miles after that. I use synthetic oil and go about 500 miles between oil changes. I have an inspection and adjustment maintenance list that I run through when I change the oil. Thing like, inspect CV boots, clean oil pan screen, check shifter linkage, clutch adjustment, etc. Takes about 1 hour start to finish.

YearMax, your adjustment could be too tight or your idle speed too high. Also, the transmission loosens up with mileage, so if you do not have some miles on it, that could explain the hard shifting.

SJ

 

Okay SJ, here is what I found. I adjusted the cluch twice with no luck. So, unwillingly Saturday night I tore the whole right hand side apart. Both clutches looked good and tight. Could not figure out why the shifter had so much play in it. Yesterday after a better inspection and a might sober I seen that while moving the shifter while watching what was happening on the right side that was exposed the shifter rod is connected to some sort of plate (thingamabob) I don't know what it's called. Anyway, it is either connected with splines or factory welded. Could not really tell for sure. This was slipping and causing it to not shifting correctly. I fired up the welder and tacked a bead around the bottom side of the rod and the (thingamabob) and viola, it's back on the road.

Thanks allot for all your help. Did not know there was a clutch adjustment. Glad I goined this board. Lots of useful info here. I hope I just contributed.